Just a quick update folks to let you all know where we are.
Carrying on from the vacuum formed 3mm ABS headlight mounting bracket, is the 'profiling' stage. Basically, cutting the final part down, drilling the holes, cutting the headlight apertures and then the final trimming around the base. Sounds easy ................. but from what I've already experienced, this is by far the hardest part. So many different tools and processes involved also makes this quite a lengthy procedure, it's part of my workflow that I'm still working on ................ what to do next and how to do it correctly. And safely, as now I'm having to use high speed cutting tools, routers and various cutting mills.
The first part is to cut away the waste material, cutting plastics isn't always as straight forward as it seems, as the incorrect type of blade combined with too high a cutting speed tends to fuse ( or melt ) the plastic sheet back together again behind the cutting blade. But this is possible with correct blade and speed set on a bandsaw >>
A quick test to see if the forth mounting point for the fixing bolt will work. Looks OK at the moment >>
Next up is to cut the base off ............... here is where the problems began ! Because my part is now 2mm bigger all the way round, the part doesn't fit in my original cutting jig >>
I worked out last time that greater accuracy in cutting the base off was achievable only from inside the part, with the part upside down, so I want to continue using this method.
My original cutting jig >>
So I need to router out a section of the jig down 2mm to make the jig slightly larger >>
As I have a number of rotary tools, like Dremels, routers and milling machine ................... wouldn't it be great if I could use standardised router and cutting bits in all those machines, it would certainly negate buying different sets of bits for each machine wouldn't it !? The 'Proxxon' milling machine on the left runs between 900rpm - 6,000rpm and the Makita trimmer runs between 10,000rpm - 30,000rpm so that means I could choose which machine to use for any given task or material used.
Not on your life ! every single machine has a different adaptor ! nothing fits, nothing' interchangeable
The router bit set I have are for 8mm shanks ( 8mm and 12mm being the European standard sizes ) because that' the size of the adaptors ( collets ), which also means I can't shop for router bits in the UK as they're 'imperial' ! ( 1/2" and 1/4" ). So now I'm on the hunt for a 6.35mm ( 1/4" ) adaptor ! >>
Here's one method I could use ................... but you certainly wouldn't use this tool and router bit free hand ! even looks dangerous ! >>
So now I'm having to build a router table
Anyone know of a decent supplier in the UK that can supply spiral upcut router bits ? as after spending all day searching on the Internet yesterday ( and part of last night ) I'm getting very tired of looking ! I would prefer to order router bits from the UK as the prices over here for tools are extortionate. Sometimes as much as €90 for a basic router bit that's around £30 in the UK.
TURK
Carrying on from the vacuum formed 3mm ABS headlight mounting bracket, is the 'profiling' stage. Basically, cutting the final part down, drilling the holes, cutting the headlight apertures and then the final trimming around the base. Sounds easy ................. but from what I've already experienced, this is by far the hardest part. So many different tools and processes involved also makes this quite a lengthy procedure, it's part of my workflow that I'm still working on ................ what to do next and how to do it correctly. And safely, as now I'm having to use high speed cutting tools, routers and various cutting mills.
The first part is to cut away the waste material, cutting plastics isn't always as straight forward as it seems, as the incorrect type of blade combined with too high a cutting speed tends to fuse ( or melt ) the plastic sheet back together again behind the cutting blade. But this is possible with correct blade and speed set on a bandsaw >>
A quick test to see if the forth mounting point for the fixing bolt will work. Looks OK at the moment >>
Next up is to cut the base off ............... here is where the problems began ! Because my part is now 2mm bigger all the way round, the part doesn't fit in my original cutting jig >>
I worked out last time that greater accuracy in cutting the base off was achievable only from inside the part, with the part upside down, so I want to continue using this method.
My original cutting jig >>
So I need to router out a section of the jig down 2mm to make the jig slightly larger >>
As I have a number of rotary tools, like Dremels, routers and milling machine ................... wouldn't it be great if I could use standardised router and cutting bits in all those machines, it would certainly negate buying different sets of bits for each machine wouldn't it !? The 'Proxxon' milling machine on the left runs between 900rpm - 6,000rpm and the Makita trimmer runs between 10,000rpm - 30,000rpm so that means I could choose which machine to use for any given task or material used.
Not on your life ! every single machine has a different adaptor ! nothing fits, nothing' interchangeable
The router bit set I have are for 8mm shanks ( 8mm and 12mm being the European standard sizes ) because that' the size of the adaptors ( collets ), which also means I can't shop for router bits in the UK as they're 'imperial' ! ( 1/2" and 1/4" ). So now I'm on the hunt for a 6.35mm ( 1/4" ) adaptor ! >>
Here's one method I could use ................... but you certainly wouldn't use this tool and router bit free hand ! even looks dangerous ! >>
So now I'm having to build a router table
Anyone know of a decent supplier in the UK that can supply spiral upcut router bits ? as after spending all day searching on the Internet yesterday ( and part of last night ) I'm getting very tired of looking ! I would prefer to order router bits from the UK as the prices over here for tools are extortionate. Sometimes as much as €90 for a basic router bit that's around £30 in the UK.
TURK
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