I built this chamfering assembly to utilize my Bosch die grinder in lay down mode. Unfortunately this model is not variable speed, but the rpm seems to work about right. This has the cutting action on the side of the 0.250" carbide end mill. I made a prior version using a router where it cut n the end, but I didn't like the potential of metal shavings finding their way into the motor windings. Die grinder cooling vents are more protected. But as it turns out, the firewall, base & 2 side members make a nice natural confined box so the chips drop down safely into that natural cavity, nothing back to the motor.
To adjust the chamfer depth, I loosen the clamp handles, turn the knurled knob which jacks up the V frame up or down. The frame movement is confined by the UHMW slide rails. The base is 1/2" MDF. My original plan was to mount the MDF base to a bench top, but I later decided to add a keel from same material to hold it the bench vise. A lot more convenient to quickly set up & store away.
The V rails were designed around 3/16" thickness but I realized after making them what I had in my scrap box was under that size & kind of garbage mystery material from sheet metal stamping. After filing & straightening it still looked like crap so I gave it the Tremclad spray bomb treatment to prevent rust. In hind sight it’s probably going to just scratch off so maybe I’ll find some nicer material one day. I wanted the exposure to the cutter as minimum as possible, so some fiddly setups to make the notch.
Anyway, the homebrew machine turned out ok & the test cuts look pretty good. You can zip through the edges pretty quick, quite smooth & consistent. Never feels like it wants to throw the part back in your face. The aluminum tester is about .070" chamfer, the steel is about .020"
To adjust the chamfer depth, I loosen the clamp handles, turn the knurled knob which jacks up the V frame up or down. The frame movement is confined by the UHMW slide rails. The base is 1/2" MDF. My original plan was to mount the MDF base to a bench top, but I later decided to add a keel from same material to hold it the bench vise. A lot more convenient to quickly set up & store away.
The V rails were designed around 3/16" thickness but I realized after making them what I had in my scrap box was under that size & kind of garbage mystery material from sheet metal stamping. After filing & straightening it still looked like crap so I gave it the Tremclad spray bomb treatment to prevent rust. In hind sight it’s probably going to just scratch off so maybe I’ll find some nicer material one day. I wanted the exposure to the cutter as minimum as possible, so some fiddly setups to make the notch.
Anyway, the homebrew machine turned out ok & the test cuts look pretty good. You can zip through the edges pretty quick, quite smooth & consistent. Never feels like it wants to throw the part back in your face. The aluminum tester is about .070" chamfer, the steel is about .020"