CNC Milled Aluminum Sun Visor Thingy

[Ranchero50]

As requested, It's coming, pics tomorrow.

Spent the day working on the contour G code for the mill. Spent the evening building and running the two first steps to mill the saw cuts ends to size. No idea on price, I whacked a 1" x 2" length of metal up to make these prototypes. Started with 28, down to 26 (setup piece and an oops).

More to come.

CAD of the profile and the cuts to get a 1" x 1.75" block there. It has a couple relief holes drilled before the cuts start:



Jamie

[MAK]

Great! Can hardly wait to see the end result. I'm sure it will look great.

[stangconv]

Well you know I am in on all your billet pieces.... PM when its ready!! Oh yeah my visor thingy is also connected to my mirror... Probalyl need a new mirror hey?

Oh yeah I got the light bezel and the ashtray door puller.... AWESOME!!!

[fitzwell]

shoot me a pm when it's ready. What else do you have in the works?

Normally, i'm not a big billet fan, but that, along with the ashtray pull will look perfect in the 68.

[pollock]

Outstanding!

[Joshpow]

How bout the cd player plates? Glad to see progress on the visor mounts. Pics, PLEASE!!!

[zakt]

put me down for the visor piece as well, dont care for the plastic

Todd

[Ranchero50]

Doesn't look like much, but there are four of five steps done to the part in these pic.



Side milling the mounting recess. Had to go real slow to keep the tool from chattering in the cut.


Tomorrow at work I hope to get the sketches redrawn in BobCAD so I have a better record of the process.

Jamie

[390F100]

That looks sweet, man do you have some talent...

[Ranchero50]

Still plugging away at the G code...

Here's a screen shot of tonights pain. All the pretty blue lines are roughing cuts that I needed to plot before getting to the final rough and finish cuts. .020" off each pass to keep it from chattering the tool to death. The program I'm using isn't real strong so I could only transfer a few segments at a time or the CAM program got confused, or at least I'll blame it on the CAM program. 12hrs of work, half hour nap, dinner and two hours of numbers and lines and I'm a bit burnt.


Jamie

[ezernut9mm]

you know i'm in line whenever your ready jamie.

[Ranchero50]

OK, 365 lines of code and several trips out to dry run them in the machine later I have a working program. Hope to build the fixture tomorrow and cut some aluminum.

Keep fingers crossed...

Jamie

[Ranchero50]

OK, I have one prototype made. Took almost 26 minutes to mill out and the finish isn't that great and there was seom loading on the inside cut. Otherwise it turne dout pretty nice and follows the original part nicely.

Pics tomorrow, the cell phone died.

Jamie

[Ranchero50]

OK, pics are here, cell phone of course... so they suck.

The fixture to hole the part, 2" x 2" x 8". Has a step milled on the end as well as the reverse contour and two mounting screw holes drilled and tapped.



Three relief holes drilled.



Milling the contour, about half way done here. Note I'm using a 2" lead 3/8" end mill to cut the whole thing in one pass.



Finished part. looks good on this side.



The good...



The bad... The long end mill deflected while cutting so I need to overcome this before making parts. The divit is where the spindle loaded up in the cut because there wasn't anywhere to put the extracted metal.



I'm not sure what I'm going to do. I could just have it redo the finish cut a couple times and hope it cleans it up or redo the program to cut it from both sides, but then I'll have some mismatch where the cuts meet. I'm not real happy with this part, but I expected some deflection.

It's raining out today so maybe I'll go down and play with it some more.

Jamie

[stangconv]

looking good to me!!

I cant wait to get it!!!