The welding and fabrication area is almost ready. The area is located in the South-East corner of the barn. It is about 14×20 feet, not real big, but should do well for our purposes. We covered the outside walls with steel panels, which assures there is no exposed wood in the shop. A six-foot high fence with a gate was built to control access to the area. An exhaust fan will be installed on the far wall to provide good air exchange. The area has it’s own electrical sub-panel, so installing power for welding machines should be easy. A bit more relocating the material on the west wall, and we should be able to start setting up equipment. We a very nice oxy-acetylene rig and also some equipment that members are willing to loan to get us going.
With the completion of the downdraft table/powder coating booth, and the acquisition of a new oven, we now have the facility to do powder coating. Powder coating is a process where a dry powder-like paint is applied to a metal piece using electrostatic attraction. The piece is then baked in an oven, causing the powder to melt then polymerize into a very durable coating. Here’s an example. This is a butterfly cut from a piece of 1/4″ steel using a plasma cutter. The butterfly was cleaned and then blasted in the abrasive blaster to remove the mill scale and give a nice even surface for the power coating to adhere to. After this point in the process you should use gloves to protect the clean object from oils on your skin. Oils on the surface of the part are not good for the powder coating. The powder is then … Read More
A new Downdraft Sanding Table was built in The MakerBarn. The table has a large squirrel-cage blower from a 5 ton whole-house air conditioning/heating unit. The blower pulls air down through the table top, filters the air with a two-stage filter, and blows it back into the room. The unit moves a lot of air, and can be used for cleaning the air in the finishing room while using the stationary sanders. The hood allows the unit to also serve as a powder-coating spray booth. The unit is 60″ wide, 30″ deep, and 65″ high. It was built using pre-finished birch plywood. This is the same type of material used by cabinet makers for internal shelves on kitchen cabinets. It has a tough epoxy finish that is easy to keep clean. The table top is a grid made from the same plywood. There were over 400 dado cuts made … Read More
This machine will help open new possibilities for makers at The MakerBarn. The machine is in excellent condition. It has a 48″ table with movements of 36 x 12 inches. The Sony digital readout has a resolution of 0.0002 inches for very high precision. Installing the machine was easy, except it did need quite a bit of cleaning. It is now up and running so come visit and see what can be done. Instruction on the machine will be on a one on one basis making a small project to help familiarize the maker with basic metalworking methods.
Today Greg and I extended the dust collection system and connected it to the belt sander and the router table. The sander is awesome. We currently have 80 grit belts for fast stock removal, and several other grits up to 220 for finish sanding. The machine is somewhat complex to operate, but still not hard to learn. If you want to get qualified, let me know. We will be changing the V-belts and adding automatic controls for the air supply, but the machine can be run right now.
Big belt sander – We are always trying to improve The MakerBarn, adding new tools and materials. Recently we had a very generous donation of a Sheng Shing SDM-15 wide belt sander. This machine uses a 5HP motor to power the 16×48″ sanding belt. The belt oscillates back and forth, which helps lengthen belt life and avoid streaking the wood being sanded. It can sand a 15″ wide swath, but being open ended on one side, the operator can rotate his panel and sand a piece 30″ wide! The machine weighs about 800 pounds and is very solid. When we received the machine is was complete, no missing parts. It even came with two copies of the manual. The machine was built in October 1996, so we just missed its 20th birthday. The sander was also in good condition except that all the internal pneumatic tubes had disintegrated. Not a single … Read More
The Sieg Super X3 is now at The MakerBarn. It has a longitudinal travel of 17″, crossfeed of 5.75″ and the head can be moved 15″. All three of these movements are displayed on the DRO. The quill has a travel of 2.75″ and has its own digital readout. We should be able to do some very precise work on this machine. What’s your first project going to be? Soon I’ll post a shopping list for those expendable tools each member may want to buy. The shop will provide clamp-kits, vises, chucks, collets, and other larger items.
The stand is finished, well, until we decide to make some improvements. The stand has small iron casters to make it easy to move, but also has leveling screws to level and lock the machine in place. Now we await the arrival of the digital readout (DRO) system. This consists of a display units and three glass scales. The linear glass scales are packaged in aluminum spars that protect the scale and keep it free from dust and dirt.. The readout device has a resolution of 0.005mm, which is about 0.0002″!
A new addition for the shop. This small milling machine uses the same type of tooling as a Bridgeport style mill. So it should work well for use until we can get the larger machine. I will be building a stand and installing a Digital Readout, so it will be a couple of weeks before we can move it to the barn. With this machine we will be able to machine plastics, wood, and almost any metal, including steel. Each member who wishes to use the machine will have to supply their own cutting tools. This would typically be a set of end-mills, which is not too expensive. When learning to use the machine, it is not uncommon to break or otherwise ruin cutting tools, so it’s best if each person is responsible for their own. I’ll make some sort presentations at upcoming meetings about operating the machine tools, so … Read More
It didn’t take long. By the time I got this blog posting organized, the class was already filled. Never fear, there will be additional classes in the near future. The class will be concentrating of getting members certified to use the two CNC routers we have. The small router, “Mini-Chop” was primarily designed for mechanical etching of circuit boards. Its super precise control of the Z axis also makes it great for engraving Romark type plastic. This is the material with a thin top layer of plastic over a thicker base of a different color. We also have “Robo-Chop”, designed and built by member George Carlson. This machine has a 26×48″ build space and a 3HP water cooled spindle. It is on loan until we can purchase our own high-end CNC router. Both routers use the Mach3 control system, so operation is pretty much the same for both machines. The … Read More