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#2946590 - 01/25/10 05:10 AM Re: . New Simpit build ***** [Re: PropNut]  
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f15sim Offline
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Oh by all means, have at! biggrin

I still need to add the lettering to the landing gear indicators for my sub-panel.

You need to post updated pics of your cockpit. smile

g.


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#2946709 - 01/25/10 02:00 PM Re: . New Simpit build [Re: f15sim]  
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As soon as I find a big enough stick to stuff its guts back in I will wink


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#2974509 - 03/11/10 02:10 PM Re: . New Simpit build [Re: PropNut]  
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Hello fellow simpit addicts! I have been away from the forum for a while do a Mad Scientist bit out in the shop. With advice from Gene, CNCzone.com, and videos on Buildyourcnc.com I have striven to achieve automation! MUAHHAHHHAAA! (really should stay on my meds)

What I have actually achieved is the building of a 4x8 CNC router table. Programing goes in, parts cut to size come out. I built my creation out of MDF and surprisingly it is a rock solid. I have only run a few jobs on it so far (waiting for better end mill bits) but I will soon start working on the plans for "Generic Simpit Mark II".

The first things I want to work on are instrument panels, I need to figure out what material they are going to be fabricated out of...aluminium or plastic? I want backlighting on the lettering so they will be etched into the material also.....Oh boy Oh boy Oh Boy!

Thanks for your advice Gene!


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#2974518 - 03/11/10 02:23 PM Re: . New Simpit build [Re: PropNut]  
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Graham, WA
Welcome to the Fraternity of Evil Geniuses. biggrin

If you're going to cut aluminum, I was pointed to a pair of Onsrud 2 flue up-shear bits:
40-107 .25" and 40-101 .125". They're roughly $5 each. The ShopBot forum is down at the moment or I would let you know what the recommended feed & RPM is for cutting aluminum. (As soon as I get the info I'll update this message)

The bits can be purchased from Ballew Tools - http://ballewsawandtool.com/

If you want to get further into tips & such on exploiting your new Awesome Toy Creator, email me privately - no need to clog the forum with it. (Unless people want to see it?)

g.


Proud owner of 80-0007
http://www.f15sim.com - The only one of its kind.
http://geneb.simpits.org - the Me-109F/X Project
#2974523 - 03/11/10 02:33 PM Re: . New Simpit build [Re: f15sim]  
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PropNut Offline
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Greenville, Michigan
Perhaps we should start a CNC thread, giving tips, tricks, build information (perhaps not advice from me as that would lead to an extended hospital stay) and share gcode, and vector files.

Thanks for the link, lots of goodies there. I have those bits on their way already (different brand though). I would very much like more information on feed and RPM for Aluminium and brass. I plan on building a new PC case for my office from 1/4" brass plate. See the link in my signature for a better idea of why.


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#2974544 - 03/11/10 03:19 PM Re: . New Simpit build [Re: PropNut]  
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f15sim Offline
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Graham, WA
Using those bits I specified, use .8 IPS (inches per second) for x & y moves, and .5 IPS for z (plunge) moves. RPM should be 18,000.

You'll get hot chips so it would be a good idea to set up an air cooler on the bit. I built a cooler that is fed directly from my air compressor. It uses a ball inflation needle as the output. The little side hole in the tip should be covered up as well. If you hit my YT page, you can see it in use when I was cutting some aluminum parts.

I don't know what the right feed & speed would be for brass - you'll have to experiment.

Also, do NOT take full depth passes! When cutting non-ferrous metals, I would recommend no more than .015" for the 1/8" bit and .100 for the 1/4" bit. The issue is machine deflection due to load. (that and without flood coolant you'll likely have chip re-weld issues and snap the cutter in half)

cool case. smile

g.


Proud owner of 80-0007
http://www.f15sim.com - The only one of its kind.
http://geneb.simpits.org - the Me-109F/X Project
#2974710 - 03/11/10 08:15 PM Re: . New Simpit build [Re: f15sim]  
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MudPuppy Offline
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Appalachian foothills in Virgi...
Built your own CNC machine, wow! If you are able to post any photos I would be interested to see what it all looks like.
I lurk around some on the mycockpit.org forum and noticed they recently started a sub-forum to discuss CNC routing of control panels, controls etc.. You might give a gander at what they've set up.

As for me....if I can manage a "basically" straight line with my powersaws I'm feeling like the king of DIY'ers. Hats off to you for putting all together and making it work.
Regards,
Derek

#2974740 - 03/11/10 09:08 PM Re: . New Simpit build [Re: MudPuppy]  
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PropNut Offline
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Here you go, some pictures I took during the build. I started on Sunday with boxes full of parts and yesterday I finished after running several test jobs. Today I made a pen attachment to use for my other addiction, R/C airplane building. I can lay out wide roll paper and use the table to draw plans, etc. I can then cut out those plans using the CNC, life is wonderful biggrin



I decided to use my outfeed table as the CNC table. There is 9+ feet off the sawblade for clearance if I am cutting anything wider than 36", I can still go 12'+ to the wall for cutting Corian countertop material. (perhaps I will use the CNC to cut them for now on, muahahhahah!)



You can see the rails (X-axis) attached to the table sides now.



The gantry (Y axis) assembled and attatched to the X-axis rails.



The Z-axis and spindle motor (Bosch 2.25 HP router head) attached.
Note the chain drives on both the X and Y axis'. This works very well and is increadibly accurate (surprised me as I didnt expect pinpoint accuracy but I got it).



The Z-axis showing the 12"x10tpi (teeth per inch) lead screw. I need to clean up the wiring an perhaps put a coat of paint on the raw wood. I am pretty sure I am going to design a prettier setup and use this machine to cut out the next version though, so maybe I will leave the wood as is.



A cheap P4 2.2ghz all in one PC (Omnitech) from Ebay (79.99) completes the system.

Parts:
V-Groove roller bearings (3/8)for the slides (VBX.com).
1/8"x3/4"x8' Aluminium angle from Menards as slides.
3@10' #40 roller chain from Northern Tool
Sprokets and idlers from Spacely Space Sprokets (ok, from McMaster Carr) ( tooth #40 main sproket)
Gecko G540 breakout board and drivers
Keling 387oz motors (1 for Z, 1 for Y and two for X)
48v power supply (also from Keling)
lots of sweat, nuts, bolts...and...oh yeah, a bit of blood (darn MDF soaks it right up)
Mach3 control software
Design CAD for making pretty pictures to size.


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#2974767 - 03/11/10 10:26 PM Re: . New Simpit build [Re: PropNut]  
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Valisk_61 Offline
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Widnes, UK
Nice work PropNut smile

I bought a small CNC to help with my backlit 'pit panels and small components. It's become a whole new hobby in itself. Here's a pic if anyone's interested:




At $580 delivered, it's right at the bargain basement of CNC machines, but it's surprisingly capable. There's quite a learning curve, especially if you're new to 3D modelling smile


FS~Valisk 'Val'
www.skiesoffire.org

"I've never seen the Icarus story as a lesson about the limitations of humans. I see it as a lesson about the limitations of wax as an adhesive." - Randall Munroe
#2975708 - 03/13/10 04:11 PM Re: . New Simpit build [Re: Valisk_61]  
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MudPuppy Offline
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Appalachian foothills in Virgi...
Just re-read your post and viewed the pics again. Great job and an excellent addition to your shop! Thanks for posting the photos.
Derek

#3017801 - 05/24/10 04:44 PM Re: . New Simpit build [Re: MudPuppy]  
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PropNut Offline
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Greenville, Michigan
Derek, thanks and I am glad you have enjoyed the pictures as much as I have building the pit and CNC.

Valisk, I couldnt agree more. It was EASY building the CNC table, but the learning curve for the software is a killer. I broke down and purchased Vectric's V-Carve Pro (bundled with Photocarve) and it has taken the headache out of to software issue. Thanks to Gene for recommending it to me. The price is steep (as much as you paid for your entire table!) but well worth it in my opinion.

David


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#3018408 - 05/25/10 01:05 PM Re: . New Simpit build [Re: PropNut]  
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f15sim Offline
More projects than sense!
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Graham, WA
The thing about CNC is that you could have a multi-million dollar machine and still produce junk because the tool paths aren't any good. smile VCarve Pro has a HUGE number of post-processors that allow you to produce code for just about any CNC machine on the planet.

The cool thing about Vectric is that not only is their documentation top notch, but you can download an evaluation copy that'll do everything except generate the CNC instructions. VCarve Pro has a "preview" mode that is so accurate that providing you don't make any mistakes setting up the machine, you'll end up with a part that matches the preview exactly.

g.


Proud owner of 80-0007
http://www.f15sim.com - The only one of its kind.
http://geneb.simpits.org - the Me-109F/X Project
#3018506 - 05/25/10 03:54 PM Re: . New Simpit build [Re: f15sim]  
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Valisk_61 Offline
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Anything to make life easier. smile

I was thinking of buying Vectric's Cut2D application - it seems very reasonably priced and judging by the information on the website, it should be able to generate the simple shapes I'm after.


FS~Valisk 'Val'
www.skiesoffire.org

"I've never seen the Icarus story as a lesson about the limitations of humans. I see it as a lesson about the limitations of wax as an adhesive." - Randall Munroe
#3018543 - 05/25/10 04:46 PM Re: . New Simpit build [Re: Valisk_61]  
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PropNut Offline
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Valisk, I would bet that you quickly grow out of Cut2D. V-Carve Pro has increadable versitility, including some 3D aspects that it is well worth purchasing. \

Gene, I 100% agree with the preview feature. It is spot on acurate, and shows the, in my case many, mistakes before you waste material.

David


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#3031651 - 06/15/10 06:00 AM Re: . New Simpit build [Re: PropNut]  
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WOW..all I can say really. I've just read your entire thread David,great stuff!!

I like the "generic" aspect a lot. The only question is, when you redo your panel, will you be shifting some of the switches down onto side walls, or are you leaving them on the MIP?

I can probably get you good pictures of an SE5a panel if you wanted to recreate that as well as the shape.


Anyway, VERY jealous of your woodworking skills.

cheers


Darryl


PRU Spitfires..alone, fast and stealthy.
In memory of Flt Lt Tony Hill who, on 5 December 1941, at the request of Doctor R V Jones, successfully photographed a small "Würzburg radar" at Bruneval on the French coast. This from a height of only 200 ft, at high speed, under fire and from a camera mounted obliquely behind the cockpit.
#3031871 - 06/15/10 02:43 PM Re: . New Simpit build [Re: DarrylH]  
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Reschke Offline
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Reschke  Offline
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Vestavia, AL
Ok Propnut and Gene big question here just so I will know for the future.

What has been your total investment in building your own CNC machine versus buying a used one for the sizes you are working with?

I am asking because I just bought a house with a huge basement and the wife is ok with me putting in a small wood/machine shop to do home projects and a few "side" jobs to help keep me sane when the real paycheck job gets me down.

Last edited by Reschke; 06/15/10 02:43 PM.

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#3031953 - 06/15/10 04:23 PM Re: . New Simpit build [Re: Reschke]  
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PropNut Offline
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Hi Reschke,

I believe Gene purchased a shopbot turn key setup (I looked into them, really really nice systems). I built mine (as you saw) for a total of 2294.69, this includes all the software (900.00 worth) electronics and MDF. My first setup was with hand cut parts (X Axis and Y Axis carriage parts) and MarkII with CNC cut Axis' (Mark I to make Mark II, lol). The second is much much more precise that the first. Everything else was just straight cut MDF parts that you can do on a table saw. Here is a list of my expenses:


Homemade CNC Router Expense List
by cncroutersource.com
Qn. CPU Total %
Structural Materials
Aluminum 6 $15.87 $95.22
Wood 1 $25.00 $25.00
Steel 0 $-
Misc. $-
Sub Total $120.22 5%
Fasteners
Bolts 1 $151.71 $151.71
Eye-bolts 1 $21.30 $21.30
Nails $-
Misc. $-
Sub Total $173.01 8%
Linear Bearing Assymbly
Linear Rails/Rods 0 $-
V-Groove Bearings 16 $10.26 $164.16
Rack and Pinion $-
Misc. $-
Sub Total $164.16 7%
Linear Drive Components
Leadscrew/Ballscrew 1 $36.81 $36.81
Drive chains 3 $16.48 $49.44
Flange bearings 2 $7.46 $14.92
Motor Shaft Coupler 1 $15.98 $15.98
Sprockets 3 $8.97 $26.91
Collars for sprockets 3 $8.62 $25.86
Idler Sprocket 3 $11.50 $34.50
shipping 1 $5.00 $5.00
Sub Total $209.42 9%
Spindle
Router Motor 1 $- $-
Motor clamp 1 $- $-
Speed Controller (if needed) 0 $-
Extra Collets (if needed) 0 $-
Misc. 0 $-
Sub Total $- 0%
Services
Machining Services 0 $-
Lathe Services 0 $-
Misc. 0 $-
Sub Total $- 0%
Electronics
Power supply 1 $50.00 $50.00
connectors $-
Limit Switches 8 $3.09 $24.72
Electrical Tape $-
Stepper Motors 4 $58.15 $232.60
Stepper motor wire 1 $25.40 $25.40
Misc. 1 $8.45 $8.45
Sub Total $341.17 15%
Controller
Gecko G540 1 $299.00 $299.00
Breackout Board (in needed) $-
Misc. $-
Sub Total $299.00 13%
Computer 1 $106.30 $106.30
Sub Total $106.30 5%
Software
Controller Software 1 $166.42 $166.42
CAM Software Vcarve Pro+Photocarve 1 $699.99 $699.99
Misc. $-
Sub Total $866.41 38%
User Interface/ Control Panel
MPG Weels 0 $-
Emergency Stop Buttons 1 $10.00 $10.00
Axis Select Buttons $-
Joystick 1 $5.00 $5.00
Misc. 0 $-
Sub Total $15.00 1%
Extras
0 $-
Coolant System 0 $-
Misc. 0 $-
Sub Total $- 0%
Total $2,294.69


F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#3031967 - 06/15/10 04:45 PM Re: . New Simpit build [Re: PropNut]  
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f15sim Offline
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Graham, WA
My ShopBot was purchased in 2007 for roughly $17,500. That didn't include VCarve Pro or some of the other software I purchased with it. It's not aimed at the hobbyist market, but that's what I use it for. smile

If you buy a 'bot, get the 60" wide model. I ordered the PRT 96 Alpha which will take a 4x8 sheet of plywood. Had I known that most Baltic Birch plywood came in 60" x 60" sheets, I would have purchased the other machine. smile

g.


Proud owner of 80-0007
http://www.f15sim.com - The only one of its kind.
http://geneb.simpits.org - the Me-109F/X Project
#3031971 - 06/15/10 04:55 PM Re: . New Simpit build [Re: f15sim]  
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PropNut Offline
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Greenville, Michigan
Here are more detailed pictures of my build:








You can see I added a 4" vacuum attachment. I saw a YouTube video for a similar setup and thought...are you really trying to sell these to people who build CNC machines? (give the company credit, their product is worth the money but why not make my own?)





I had to have a case to mount the electronics, etc so I thought a cabinet to hold the PC would be nice also. Not really happy with it as the ergonomics is not "just right" but I will work on MKII of the PC cabinet this winter.










I prettified the new parts up a bit with some graphics, considering MKI did the work and MKII is even better you can get a sense of how happy I am with the result. I can cut a 4x8 sheet up on the table with some room to spare. As Gene mentioned, if you get your baltic birch in 5x5 then a 60" cutting surface might be a good idea. I get my Baltic Birch in 4x8 sheets though(my wholesaler has both in stock and it is slightly cheaper in 4x8, didnt used to be though).


I would not in any way claim that my homebrew is better than a shopbot, I know better, but is hugely less expensive. If I could afford it, I would have bought a shopbot. I cannot but I am very happy with my MDF monster. As the insignia on the side indicates, I have a certain sense of Serenity when working in my shop wink





Last edited by WH_PropNut; 06/15/10 05:01 PM.

F/A-18C Hornet cockpit build project:

http://hornetpits.org/index.php?topic=15.0
#3032043 - 06/15/10 06:06 PM Re: . New Simpit build [Re: PropNut]  
Joined: Mar 2007
Posts: 1,298
Reschke Offline
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Vestavia, AL
Thanks for the information. This new house we just bought needs to have some cabinets built for our new ovens and cooktop and I really think I want to make an attempt to build my wife a barn plank kitchen table. I was able to get for free an old barn/cotton storage house a few years ago off my grandparents property and every once in a while I sell a few pieces to fund a couple of new projects.


Star Citizen Referal Code
STAR-MP6J-VFH7

i7-13700K @ 3.40GHz
32GB RAM
GeForce 3060RTX
MSI MAG Z790 Tomahawk
lots of SSD's and a good old fashioned 1TB HDD
Samsung G9 Odyssey 49"
TrackIR 5 with Track Clip Pro
Windows 11 64bit
Warthog #1397...compliments of SimHQ
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