In terms of the milling setup, I have always been fighting for better centering. More consistent centering.
It’s not that I am a perfectionist, they are still a little off occasionally, but this runs was by far my best.
A problem I ran into before was how different chips were based on wear… and literally every time I would loosen any of the setup screws to reset, it would just take waaaaaayyy too long to get it back to center. It was discouraging.
This drill press attachment helps that situation immensely.
Another thing about the milling rig. I redid my chip holder thing. What I had before worked okay for mint chips, but even slightly worn chips were too loose, also I had a pretty thick piece of rubber sandwiched in as a floor, and it would actually “give” a bit and I could feel it flex under the chip when I applied the pressure.
I used this cheap thin silicone baking sheet from Amazon this time, it still stops the chip from spinning, but it’s doesn’t have any give, the chip reacts better. Pressure is more consistent.
I made the chip holder out of two pieces of 1/8 thick walnut hardwood I had laying around. I used a hole saw to cut the area for the chip. I used a file to widen it to near perfect, but then it was slightly too big .
Even a millimeter of play in the chip holder recess creates non centered cuts.
I think this was a pretty good solution. To “perfect” the chip holder area I used masking tape, to tighten the inner edges of the hole, stacking a couple layers where I thought it wasn’t a perfect circle.
This method would also allow me to add a bit more tape when it’s time to mill some bike tires. (Ahem..cough Sahara dunes 1s)
All in all, this run was the least annoying time I have had.
Pushed out a racks in less than 25mins, with no frustrations.
I use a brush to wipe out dust and debris often, even a few filings lodged in between the chip and the walls can off center the cut.
Looking at ways to keep the shop vac running and sucking up debris consistently.
I keep my blade really close to the jig, and I just leave it running as a work, I found the longer the throw, the less consistent the work was and it’s a lot faster overall with a short throw.
It’s hard to maneuver the chips in and out with this short space, and I hit my fingers occasionally on the moving bit, but not the knife portion, so it just gives you little buzz. Probably not the safest way, but for me, it’s the fastest and the best. Just takes concentration.
I use my left hand thumb, to hold the free end of the chip, and can purposefully affect the slight placement of the cut with the pressure I apply with my thumb. (Sometimes good, sometimes not so good
but once you are in this dance, where you are literally trying to hit a perfect millimeter placement, literally everything mattters.
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