CNC Mill Build Thread (Video and parts pics)

[Seabass]

Hey guys I am finally to the point where I am ready to start building my CNC mill. The project will consist of converting a Sherline CNC mill into an extended travel machine. I purchased everything I need including the stepper motors, and stepper drivers. I will be building my own controller which will house the power supply, stepper drivers, etc.

In addition to the parts I purchased, I also upgraded the head of the machine which will now give me the ability to spin 10K RPM.

The mill should have about 11 inches of Y travel and 14 inches of X travel. I will use this thread to document the build.

I have wanted to build this machine for a while and I finally have everything I need. Well I still need to order some way oil before getting officially started.

You can see the comparison between the old and new base of the machine. The new parts are much larger and have some serious weight to them. The machine should be pretty rigid once completed.

[SFC K]

I applaud you for tackling this, where as I would not have a clue even where to begin.

[328isjohn]

As a CNC Machinist...you have my attention

[flipwils11]

I applaud you for tackling this, where as I would not have a clue even where to begin.

X2, plus I'm excited you are back safe and sound stateside and can't wait to see what new parts you come up with!

[GoMachV]

Ooooooo very nice!!!!

[askbob]

[Seabass]

The controller is going to be the most challenging part of the build. I have some outside help guiding me along the way to get this thing wired up. Once I get the machine base built, I will work on a cabinet that is going to contain the computer to run the machine as well as the coolant system I am planning. The cabinet and machine is going to be one unit that can be moved as needed. Will make things much easier for me.

Once I make some more progress I will update the thread.

Jake

[myfordcnc]

The controller you're going to build is it a kit like the HobbyCNC pro kit? What about software Mach3? or the linux one? Stepper motors nema23? Don't know if you have a solution for the stepper motor covers, but I used these, their rather nice to finish of the back. Good luck on your build. I look forward to seeing it's development.

[Seabass]

The controller is not a kit and I picked out the specific parts I wanted.

Stepper motors are Gecko Nema 23s with Gecko Drives.

Picked up a Cambell Design Breakout board which gives me the option to add a 4th axis down the road as well as program coolant into the G-code for on/off.

The rest of the controller is a Chinese power supply, etc.

I will run Mach 3 with this machine. Will have to look at the stepper motor covers.

Jake

[uniquenamehere]

Nice! Very interested in how this turns out...

[Niki]

Hi Jake,
Good to see your mill project moves on.
I already have workload for your machine When can I send you offer requests and files...
By no means... take your time and build a good Monster Mill. Nice to see you are back home.

-Niki-

[Seabass]

Time to bust out the pocket book on this one.

When I initially started planning for this, I chose the A2Z monster mill conversion. The full machine requires everything I have and also a 16 inch z travel as well. I did not need 16 inches of z (up and down for those who do not know) and never will so I did not order the parts. I figured I would be able to get away with reusing the z travel for the machine I already have. The new table and saddle have raised the surface about two inches killing of the already relatively small z travel from the original machine. After doing some assembly I found out my work space is going to be super tight between the collet and material. It is too close for comfort for me and will really hamper what I have planned.

The parts for the extended z travel..........$900

In addition to the extended z travel, my motor couplers are not going to work either $150.

Then I need a few other odds and ends $50 for a total of $1100.00. Man my wife is going to freak out when she hears about this .

Basically the machine I started with is absolutely no good to me. Time to put the entire old machine up for sale to help offset the cost.

Here is a picture of what the final product will look like. I don't like the 16 inches of Z but I guess it will be there if I ever need it.

[Seabass]

After some research and some time studying the old machine itself, I have figured out a way to fix my issues without going with the extended Z travel.

First A2Z offers a Z riser block set that will allow me to raise the Z axis up to 4 inches, This will solve my problems with not having enough clearance.

The second issue is going to require a trip to another machine shop. The stepper motor coupling for the z axis is creating problems with the stepper motor I have. Basically, the shaft for the stepper motor is too long and will not allow the motor to mount properly. I first had the idea of cutting the shaft of the stepper motor but I did not want to screw up a brand new motor. The second option is to machine a new coupling that is taller giving me the room I need to mate the stepper motor to the ball screw. I sat down with the old part, took some measurements and I now have the new part ready to machine. Looks like I need to run to my dads shop to machine the part I need. I will get the new part ano'd black to match the machine. Should be a solid fix to my problem. The best part is I saved myself a ton of money by doing this. Worst case scenario, if I cant get it to work properly, I am not out much of anything.

Jake

[GoMachV]

Good thinking!

Ironic that you need a mill to build a mill. Which begs to ask....how did they build the first mill

[slow_jun]

Great,new stuff to look out for...