Kaz's Random Projects

[stioc]

Yeah, it sounds like it'll be well worth a little extra time/effort/money up front and get the garage back in a shape that's ready to go.

Fadal 3016 sounds pretty nice! Would you rather buy a used Fadal/Haas than a new Tormach for the same price? Is it because they're just better built?

 

[kazlx]

Yes, I've already grown accustomed to what I can do on the current machine. Not that there's anything wrong with a Tormach, but there's no replacement for size, rigidity and horsepower. I'm already set up to run a full size machine. I think Tormachs are fine for prototyping or hobby stuff. I don't think I could step back at this point and be satisfied. I know the Tormach would have a huge control upgrade to what I have now, but I essentially need a more capable control paired with the iron I have now. (Hindsight being 20/20, had I known then what I know now, would have passed on my current machine and laid out more cash the first time and been done). I didn't even think about not being able to helical, 3d surface, limited memory and no DNC. I thought every machine could drip feed so didn't think memory would be an issue.

 

[stioc]

That makes sense since you're basically doing production runs. I didn't know that you couldn't do those things due to its memory limitations.

 

[bullnerd]

I saw some clean, smaller Fadals on Ebay recently.

There isn't **** around here in NJ.

 

[kazlx]

Back at it. House is finally pretty much wrapped up. Working on some brackets for a customer.

 

[kazlx]

Picked up a Dake SXC saw for $1500. Love it already.

And a Gladiator workbench for $100.

 

[cspcrx]

that's a great price on that work bench

 

[stioc]

That's a sweet deal! Nice to see you're back at it. Pics of the new garage?

 

[bullnerd]

Rollin, rollin, rollin!

 

[kazlx]

that's a great price on that work bench

I thought so. I really like it. First time I've had that much bench space in my garage....and it's awesome.

That's a sweet deal! Nice to see you're back at it. Pics of the new garage?

Yea finally. The house addition was stressful and did a number on the garage. Finally getting everything sorted. Should be getting some things dialed and taking pics.

Rollin, rollin, rollin!

 

[kazlx]

Parts for a customer. I made an aluminum replica of one he cast in some sort of urethane.

My design:

Done:

Finished up a batch of the Wixey Gauge Holders. I love hard ano:

 

[kazlx]

Also picked up a Mr. Deburr tumbler for a fraction of new, with a few dividers, the lid and a ton of different media. Can't wait to give it a try. The HF tumblers aren't cutting it.

 

[4 FN 27]

Parts for a customer. I made an aluminum replica of one he cast in some sort of urethane.

Simply awesome!!!

Also picked up a Mr. Deburr tumbler for a fraction of new, with a few dividers, the lid and a ton of different media. Can't wait to give it a try. The HF tumblers aren't cutting it.

On the must have list...I have been looking for a while now. Nice score!!!

 

[kazlx]

Moving up in the world. Worked out a deal on this and now just need to get it down here:

 

[4 FN 27]

Moving up in the world. Worked out a deal on this and now just need to get it down here:

I assume the Vises you purchased come with the Machine attached?

Nice addition!!!

 

[kazlx]

Hah, yup. Except I think the vises are staying. It was too clean to pass up. Original shop makes measuring instruments. They have 4 machines that are getting replaced with Brothers since a majority of their work is drilling and tapping. Should fit my needs perfectly for now. Maybe a brand new machine one of these days, but I'm stoked on this.

I'd like to pick up some dual station Oranges for this go around, but will use my Kurt DX6s for now.

 

[stioc]

Bad@ss upgrade!

 

[Bears Fan]

I love the design of the angle gauge! Wow your shop is really growing! New mill, bandsaw, tumbler and work bench...I want to come over and play

 

[NORTON'S SHOP]

Moving up in the world. Worked out a deal on this and now just need to get it down here:

I had the same VMC when I ran my shop as a business. One word of advice, keep the main drive belt and pulleys clean, otherwise they'll start to howl and grind like you wouldn't believe. The spindle drive motor fan will **** coolant mist up past the belt and that greasy sludge builds up after a while. I ran my mill; on average; 12/14 hours per day and did the clean up about every 5/6 months. First time I had the service guy do it. After that, I did it. Service guy told me it was a poor design on Fadal's part. Other that that, it was a great mill. Ran lots of aluminum through it.

 

[humpty]

Moving up in the world. Worked out a deal on this and now just need to get it down here:

You bought a fatal?

Just kidding, that was the nickname we had for them at the shop. We beat the tar out of them and they always held up just fine. From a production standpoint they held up better than the Haas machines.

The complaint that we ever had was Fadal, Haas and others had odd controls, as opposed to a standard Fanuc, which made moving operators around a little harder but they all got used to them.

From a maintenance standpoint I never minded working on the Fatals and they were a good machine.

After a couple years away from the manufacturing world I miss those damn machines.

humpty

 

[NASTYZEN]

Congrats on the upgrade Kaz! I did warn you about the cnc addiction thing... Those are great machines, I like the high speed spindle on those. The feed rate is insane on Alu.
With a bunch of vices mounted side by side you triple quadruple production.


For what it's worth, on my Mighty mill. The travel of my Y go's about 8" beyond the table edge. So I got myself a 2" slab of Alu that I bolt to the table, that gives me the entire reach of the machine. Now on some parts, I went from 6pcs at a time in a couple of vices to 32 at a time on this fixture.

 

[kazlx]

Thanks guys! I've looked for quite a while and always kept coming back to the Fadals. I also was really looking for a Brother, but the price was right on this and it's super clean, low hours, coming from a nice shop, all that stuff. They manufacture scientific instruments, so you can imagine they take care of their machines. They have another '98 that has a 15k spindle and only 5000 cutting hours. I'd buy that too if I could fit it.

Congrats on the upgrade Kaz! I did warn you about the cnc addiction thing... Those are great machines, I like the high speed spindle on those. The feed rate is insane on Alu.
With a bunch of vices mounted side by side you triple quadruple production.


For what it's worth, on my Mighty mill. The travel of my Y go's about 8" beyond the table edge. So I got myself a 2" slab of Alu that I bolt to the table, that gives me the entire reach of the machine. Now on some parts, I went from 6pcs at a time in a couple of vices to 32 at a time on this fixture.

Hah, yea, the CNC thing has been just as bad as the machining thing. Starting with an 11" Logan and now bringing in an 8500lb CNC haha. It's so much fun. I'm really excited about this because my current machine can't drip feed, has super limited memory and can't 3D surface. It was good to start but I really feel like this machine is going to allow me to go full throttle. Plus the extra space and memory/dnc is going to let me run a lot of parts like that. I'm really looking forward to exactly what you said and upping production on stuff and maximizing efficiency with more parts/ops at a time and more unattended run time. I can't wait.

 

[bullnerd]

Congrats dude!

I worked in a shop that ran 6 fadals 3 shifts. (Ever hear of Ringle bicycle parts?)

I like them, easy to run and not so fast that they scare you all day long ! lol!

Only REAL issue I ever had was the encoder (resolver) for the Z came loose and lost position! DOH! I was standing with the doors to my side, deburring on a small drill press when I see the Z go full up! I'm thinking, that's not in the program! Before I could move it went full DOWN! Straight into the edge of a vise! That sucked. After it was fixed, never happened or ever saw it on another machine.

 

[kazlx]

I have heard if Ringle. I’m a bike nut. I’ve done a lot of research and I think it’s a good choice. My current control is a Fanuc but I’ve got a buddy that super familiar and said he can help me out with anything I need.

 

[macgyver37]

I thought your old machine had a Fanuc OM on it? It couldn't drip feed?

How do you get programs on it? Does it have the RS232 cable connector on it?

Remind me what you are doing (or did) with the old one?

(I have an OM on my machine and I load programs and drip feed without any trouble, I also do lots of 3D stuff like thermoforming molds etc. Mine is a 1992 vintage and the OM is a 'C', yours I guess could be an A or B...)

 

[kazlx]

Yea Fanuc OM, but am OM-Mate. Basically the lowest control. I’ve had in depth conversations with a good Fanuc tech and Fanuc over the phone. I’m sure it’s possible but not plausible. I send programs via 232 but there’s no tape mode or way to drip.

Ultimately from everything I’ve found, the machine was built as a true drill/tap machine. It only has 32K of memory, which fill up quick. I basically only have one program in the control at a time.

A friend of mine is buying it. He just needs a machine to do some basic profiling. If I had the room I’d keep it for basic stuff or simple extra ops but just too tight on space. Trust me, I’ve exhausted options of trying to get this to do what i want it to do. Just not worth pursuing any more. Plus, ultimately I’m stoked to have a newer machine, bigger table, more tools and some other stuff.

 

[macgyver37]

Ah, I don't have any experience with the Mate version. I also understand the desire for a larger machine.

Did you find a ride for the new one yet?

 

[kazlx]

I think i have one I just need to work out details. I’m going to move my current machine out first and plan on having the floor epoxied before bringing the Fadal in.

 

[kazlx]

 

[kazlx]

Small prototype parts for a dude.

 

[kazlx]

Got this dude mounted and rolling. Ordered the correct 7 gal bucket from C&M topline and some specific media they suggested along with the soap/compound. Got it all up and running last night and it works great. After trying to decide on mounting, I finally just drilled holes and dropped female anchors. Working great so far.

 

[kazlx]

Prepping for the new lady.

 

[kazlx]

http://vimeo.com/297175848

 

[NASTYZEN]

Wow! That beats my cement mixer big time.
Do you have the right power for your new millady?

 

[kazlx]

Wow! That beats my cement mixer big time.
Do you have the right power for your new millady?

Yes and no. I currently have a 15hp RPC that works great. My current mill is 7.5hp and I've ran it near 100% load a few times with a 1/2" endmill. RPC never had issues or missed a beat. The main motor on the Fadal is 15hp. RPCs are 'supposed' to be 2x the hp rating.

That being said, I don't *think* I'll be approaching loading the Fadal that hard, especially for the kind of stuff that I make, and I can program conservatively to avoid pulling too much juice. I have seriously considered getting a 10hp Phase Perfect, which would up my juice draw ceiling, but they also cost $3500. The 20hp is almost twice that.

I think the Fadal upgrade alone, even programming super conservatively, is going to decrease my run times by a ton, so I'll probably just go at it as is unless I get to a position where I can justify spending the money. I'm trying not to spend money to solve problems I don't have right now. I'd really rather get a few pieces of equipment that will make life easier. I'm in love with the tumbler. I was so tired of using multiple HF tumblers and still having parts that wouldn't easily fit.

FWIW, I used a cement mixer quite a bit when doing plasma parts. It worked great. I do a lot of aluminum right now and just need something super quick to prep for anodizing.

 

[NASTYZEN]

Hmm. Hate to pee on your parade Kaz. The way you calculate the hp for a RPC is spindle hp plus all axis drives hp plus coolant pump. Your looking at about 32HP right there.
I have a 45hp RPC and can run both my mill and lathe at the same time. They total about 25hp each. But my Fanuc controller is really touchy with line tension and gives me weird alarms now and again. The artificial phase crushes easy. You really have to balance the RPC just right. I had the guy who makes them come here and balance mine before it ran smoothly.
I may be getting 600V in my shop. I'll give you a deal on my RPC if it happens.

 

[kazlx]

I'm not sure the load of the axis drives. The coolant pump is only like 1/6 HP. The converter was specifically built for CNC application and has been balanced for my idler. The guy that built it is local to me, even though he's sold all over ebay. He's helped me out quite a bit and says I should be good to go on the Fadal. If I replace this, it will be with the Phase Perfect. I've actually done a lot of reading on this and there's plenty of guys running similar setups. I've ran my current setup pretty hard with the 7.5 spindle and max rapids and never had a problem. If I can run those speeds with the Fadal, I'll be good. If I start to have issues, I'll tackle it as I need to.

 

[kazlx]

She's on her way.

That's a solid crew right there.

 

[slodat]

I have the same Delta drill press.

Excited to see what you make with the new Fadal!

 

[kazlx]

It’s one of my favorite tools. I actually got a 1hp 3ph Baldor for it and a VFD. Going to convert it here shortly.