After getting my mill set up, the first thing I wanted to do was install a DRO so I wouldn't have to deal with the runout on the X and Y axes and the inaccuracy of the dial on the Z axis (dial marked in thousandths but a full turn is actually only 0.084" instead of 0.100"). Also, they are just cool! I looked all around and I was really intrigued by the ones I found on AliExpress with an actual screen instead of just numerical displays. $250 with free shipping (but plus tax). After a few days the DHL tracking showed it was in Hong Kong and the next morning it was on my porch near Seattle!
First I tackled the X scale. I put it on the back of the table because of my power feed with its stops and switch. Yes, I lose some Y travel but I don't think I personally will ever miss it. My career was as a Honda tech and whenever I would make any modifications I always felt more satisfaction when I could leave things as stock as possible so that things could be put back to original without leaving any telltale signs, even though that was unlikely, just the fact that it could. I was frustrated by the many videos I watched about mounting the X scale because no one I saw addressed what they ended up doing with the chip guard. Here is what I did:
I replaced the bolts for the chip guard with studs and made a bracket to function as a mount for the read head and a stop for the cross slide to keep from crushing anything by over-travelling the Y feed, no new holes for that.
Then I mounted the X scale to the rear of the table, did have to drill and tap holes, OK of course when needed. I mounted the read head to my bracket with screws that didn't protrude past the bracket. The read heads came with red plastic spacers between them and the scales that I assumed provided proper spacing and alignment so I decided to just keep them on there. The plastic spacers had two tiny holes on the end and two threaded holes in the read head, so I put in some tiny screws left over from working on laptops that fit correctly.
Next, I put nuts on the studs even with the outside of the scale plus a hair. Then I made a plate to back up the rubber chip guard and placed it over the studs.
Then I mounted the chip guard to the studs and put on the final nuts.
Lastly I installed the guard over the scale and cranked the Y travel all the way to the stop. Nothing crushed, my evil plan worked!
On all 3 scales I wanted to mount them so the read heads were stationary and the scales moving so the cables basically don't move or wear. True, the Y cable moves a little as the cross slide moves front to back but that doesn't amount to much. Next I moved on to mounting the Y head and scale. I took the power feed out of the way and made a bracket to mount the scale. Had to drill and tap more holes, oh well.
Then I mounted the scale to the bracket. I mounted the head to the only angle bracket that I used from the kit, it worked well. More drilling and tapping, where will it end? Since the side of the machine base isn't perfectly vertical I bent the bracket to less than 90 degrees to make the top of the bracket level.
Put the chip guard on and remounted the power feed motor.
On to the Z scale! I did lots of reading online and watched videos on YouTube before ordering the kit. I was pretty clear how I would mount it for X and Y but I was up in the air on how to mount the Z scale. It seemed so bulky to mount it right out front with everything else that's in the area, I just wasn't satisfied. Then I saw a photo (on here, I think) showing someone who had mounted the scale on the side of the head near the column with a bracket going to the clamp around the quill that holds the depth stop screw. That was the idea that gave me inspiration. There is a big opening in the bottom of the head between the quill and the column just the right size to make a home for the scale and read head. I made a little mount to attach to the quill clamp and mounted the scale to it. I had to use a little shim from the kit to make the scale end up plumb. The secret here is that the upper end of the scale is just floating free but since nothing can touch it, it doesn't get disturbed. I made a couple small brackets to mount the read head and it's all set.
Last, I mounted the arm for the display. It's a little crowded back there but I wanted it on the right side and far enough back to clear the handles for the downfeed. The kit comes with a bracket and arm but when you put the bolt through it there is no provision for tensioning the pivot, it just swings freely. To solve this I drilled the lower bracket hole larger and made a slip-fit bushing for it. I put nylon washers under the bolt head and between the bracket and the arm so now when you tighten the bolt the arm is pushed against the washer so there is tension to hold the arm wherever you push it to.
I did find that the soft aluminum arm was being deformed by the pressure before I was satisfied with the tension, so I made an insert for the end of the arm and now I can tighten it as much as needed.
I used some snap-in cable ties to route the cables along the arm and some clamps with rubber inserts to corral the cables here and there. The one on the back of the column is a little oversized so that when you lower the head the cables just slide through it.
Well, I think that's about it. I hope someone in the future will gain some inspiration from this just as I do from reading posts from others.
Rob
First I tackled the X scale. I put it on the back of the table because of my power feed with its stops and switch. Yes, I lose some Y travel but I don't think I personally will ever miss it. My career was as a Honda tech and whenever I would make any modifications I always felt more satisfaction when I could leave things as stock as possible so that things could be put back to original without leaving any telltale signs, even though that was unlikely, just the fact that it could. I was frustrated by the many videos I watched about mounting the X scale because no one I saw addressed what they ended up doing with the chip guard. Here is what I did:
I replaced the bolts for the chip guard with studs and made a bracket to function as a mount for the read head and a stop for the cross slide to keep from crushing anything by over-travelling the Y feed, no new holes for that.
Then I mounted the X scale to the rear of the table, did have to drill and tap holes, OK of course when needed. I mounted the read head to my bracket with screws that didn't protrude past the bracket. The read heads came with red plastic spacers between them and the scales that I assumed provided proper spacing and alignment so I decided to just keep them on there. The plastic spacers had two tiny holes on the end and two threaded holes in the read head, so I put in some tiny screws left over from working on laptops that fit correctly.
Next, I put nuts on the studs even with the outside of the scale plus a hair. Then I made a plate to back up the rubber chip guard and placed it over the studs.
Then I mounted the chip guard to the studs and put on the final nuts.
Lastly I installed the guard over the scale and cranked the Y travel all the way to the stop. Nothing crushed, my evil plan worked!
On all 3 scales I wanted to mount them so the read heads were stationary and the scales moving so the cables basically don't move or wear. True, the Y cable moves a little as the cross slide moves front to back but that doesn't amount to much. Next I moved on to mounting the Y head and scale. I took the power feed out of the way and made a bracket to mount the scale. Had to drill and tap more holes, oh well.
Then I mounted the scale to the bracket. I mounted the head to the only angle bracket that I used from the kit, it worked well. More drilling and tapping, where will it end? Since the side of the machine base isn't perfectly vertical I bent the bracket to less than 90 degrees to make the top of the bracket level.
Put the chip guard on and remounted the power feed motor.
On to the Z scale! I did lots of reading online and watched videos on YouTube before ordering the kit. I was pretty clear how I would mount it for X and Y but I was up in the air on how to mount the Z scale. It seemed so bulky to mount it right out front with everything else that's in the area, I just wasn't satisfied. Then I saw a photo (on here, I think) showing someone who had mounted the scale on the side of the head near the column with a bracket going to the clamp around the quill that holds the depth stop screw. That was the idea that gave me inspiration. There is a big opening in the bottom of the head between the quill and the column just the right size to make a home for the scale and read head. I made a little mount to attach to the quill clamp and mounted the scale to it. I had to use a little shim from the kit to make the scale end up plumb. The secret here is that the upper end of the scale is just floating free but since nothing can touch it, it doesn't get disturbed. I made a couple small brackets to mount the read head and it's all set.
Last, I mounted the arm for the display. It's a little crowded back there but I wanted it on the right side and far enough back to clear the handles for the downfeed. The kit comes with a bracket and arm but when you put the bolt through it there is no provision for tensioning the pivot, it just swings freely. To solve this I drilled the lower bracket hole larger and made a slip-fit bushing for it. I put nylon washers under the bolt head and between the bracket and the arm so now when you tighten the bolt the arm is pushed against the washer so there is tension to hold the arm wherever you push it to.
I did find that the soft aluminum arm was being deformed by the pressure before I was satisfied with the tension, so I made an insert for the end of the arm and now I can tighten it as much as needed.
I used some snap-in cable ties to route the cables along the arm and some clamps with rubber inserts to corral the cables here and there. The one on the back of the column is a little oversized so that when you lower the head the cables just slide through it.
Well, I think that's about it. I hope someone in the future will gain some inspiration from this just as I do from reading posts from others.
Rob
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