CNC Milled Aluminum Sun Visor Thingy

[MAK]

Looks great and like you have almsot got it. I'm sure you will figure out some way to deal with the deflection. Are the relief holes as large as they can be? Like you say, making some extra passes with shallower cuts should get it.

[Ranchero50]

The reliefs could be a bit larger, but I didn't want them to affect the final cuts. One other note is I snapped off the better of the two end mills earlier in the day while pushing too hard so this part was made with a relatively dull tool. I think I'm going to go down and just duplicate the last pass a couple times and see what that does to it.

Jamie

[mrtleavitt]

They look like they're coming along! I wish I had your skills, my whole truck would be aluminum!

[Ranchero50]

OK, round three...

Slowed down the spindle speed from 1300rpm to 500rpm and the speed from 5ipm to 3ipm and it turned out much better.

Of course when I go to put it in the truck I found out that the poor slob who drilled the holes in the cab put them in crooked and offset to the passenger side 1/4" so now when it's done and shiny I get to notice how screwed up it looks...

Now my flipp'n phone software updated and wants the puter restarted before letting me transfer the pics...

Oh yeah, the milled opening is too small for the nasty old bumpers as well. I'm just going to do another offset of the basic image to get the cuts to open it up.

Are we having fun yet?

Pix later.

Jamie

[Joshpow]

Sounds like fun. Looking good so far.

[Ranchero50]

Thanks for the support guys.

Snapped the last end mill this afternoon trying to get the slot cut out better. Before I had used the end mill as a drill to open the drilled hole and then cut from there and I had trouble with the end mill not drilling straight. This time I used it as a conventional mill and pushed a slot really slowly, but it couldn't clean out the metal fast enough, slowed the spindle and snapped off flush with the holder...

Soo, I'm going to play with the drilled holes to try and get more room to evacuate the metal in the slot. I saw a youtube video of a mill that would do slots as a series of ovals so the bit was only cutting a little bit at a time and there was room to clear out the cuttings. Could be the answer, but it's gonna be a lot of manual programming

Gonna be interesting to say the least.

Some really piss poor pics. If you squint your eyes just right you may be able to see the visor clip.




Jamie

[Happy_Camper]

Awesome work!

My hat's are off to anyone who works with aluminum. Man it loads up the bits terribly. I like working with Delrin, but it doesn't look near as nice as polished aluminum.

[Joshpow]

Lookin good. Keep us posted. How bout those radio plates? Any progress yet? Just wondering.

[MAK]

Looking good. Stick with it and you'll get it figured out. Never seems to work out right the first time does it?

[1971ford]

Jamie, lookin really good. cant wait to have one of these, ive always hated the stupid plastic styrofoamy ones.

one question though, how much movement is there for the visors to rattle in the clip? and does the clip securely hold the visor ends from falling out while driving, looks like there is enough room to do so, i know you have to have enough space to be able to easily swing the visor into the clip though.

im excited for this one (just like my awesome dome lamp cover and ashtray pull)

[Ranchero50]

Ryan, actually the first version was too tight, the rubber tips didn't want to go in at all. The new version didn't quite work out yet...

I replotted some relief holes last night and may try it again today with a normal length end mill today. Gotta see how expensive yesterdays oops's were too and order some more end mills.

Jamie

[flyboy2610]

Add me to you list for a visor clip, please!

When I was a machinist, I didn't much care for working with aluminum. It was better than stainless steel, though! I DESPISED that stuff!!!!!!!!!

[Ranchero50]

Flyboy, I don't mind the work, it's just different from anything I've done before so it's a learning curve. Usually I do the design work and the machinists make the parts or I'll go back and help them out.

Here's a cool little part that made life much better at work. It's the frame of a guard / paper guide that got a sheet of teflon clamped to it. Ended up making eight of them for various presses and they are talking about rolling the design out through out the company.





Today I left the mill off and concentrated on getting the maple wood pile small enough to get the bass boat put away until I get the truck back together. Then it's getting the seadoo swap so it'll be like this;

http://www.youtube.com/watch?v=MqolaElSVAI

Jamie

[sideoilerfe]

As always, awesome job!!!

[Ranchero50]

OK, round four, or is it five... Since I had to resize the part so the visor tips would actually fit I'm going to upsize the drill bit and try again. Got some more used bits and a couple new ones. so maybe some pics later tonight.

Cracked my skull at work Wednesday and had a migrain all day today so hopefully this goes well.

Jamie