{"id":392,"date":"2009-11-18T11:35:26","date_gmt":"2009-11-18T16:35:26","guid":{"rendered":"http:\/\/soulysolar.mudventions.com\/?p=392"},"modified":"2009-11-18T12:32:25","modified_gmt":"2009-11-18T17:32:25","slug":"the-ozo-gets-a-new-saddle","status":"publish","type":"post","link":"https:\/\/soulysolar.mudventions.com\/?p=392","title":{"rendered":"The OZO gets a new Saddle"},"content":{"rendered":"

Its time now to build a custom piece of hardware to mount the router to the OZO. \u00a0Research on the web indicated that people were using MDF<\/a> for this kind of work. \u00a0Its dimensionally stable, and easy to machine, though the dust can be kind of toxic. I’ve never worked much with MDF before, preferring real wood or plywood to this glued up particle board.<\/p>\n

Being an avid scrounger, however, there where a few pieces laying around the shop. So, I decided to use it as the base material for this build. Since I didn’t have a long enough endmill to make it all the way through the 3\/4″ material and didn’t know if the current spindle would be up to the task anyway, I made it the old fashioned way, with hand tools and brute force. First I drew the design in Rhino, then, printed and transferred it to the wood with carbon paper.<\/p>\n

\"spindle00-640x480\"<\/a><\/p>\n

<\/p>\n

The next trick was getting the hole cut in the wood. \u00a0I started with a large, cheap, wobbly, hole saw from harbor freight, slightly smaller then the final hole size. \u00a0After the initial hole was punched out, I used a course rasp drill bit to bring the hole to very near the final dimension, then finished with sand paper. \u00a0After much effort, trying to fit the router, marking the tight spots, sanding them down, etc… \u00a0I finally got the the router to slide smoothly into the hole.<\/p>\n

\"spindle06-640x480\"<\/a><\/p>\n

At this point the entire shop was covered in micro fine particle dust from the MDF.<\/p>\n

A jigsaw was then used to cut out the overall shape. \u00a0I clamped a piece of angle aluminum to the board to act as a guide for the saw. \u00a0The cuts made using the guide were pretty straight, however the smaller cuts that I made by hand, wobbled off course quite a bit, also the saw angle from top to bottom was hard to control and resulted in some uneven cuts. Next I devised a clamp for the mount so I could drill a straight hole. \u00a0This made me very nervous considering the amount of time I had just spent making the larger hole perfect.<\/p>\n

\"spindle01-640x480\"<\/a>
\nHere is a shot after the hole is drilled with the bolt inserted and the router clamped down.<\/p>\n

\"spindle02-640x480\"<\/a><\/p>\n

At this point I was starting to regret my choice for using the MDF. \u00a0I should have made everything wider and thicker to accommodate the bolts\/screws. \u00a0It seemed too weak to just bolt to a back plane. \u00a0I cut some small support strips and glued the whole mess together. \u00a0Ahhhhhh Clamps, MMMMMmmmmmmmhhhhhaaaaahhhh!!!<\/p>\n

\"spindle03-640x480\"<\/a><\/p>\n

Finally I sanded a bit, added some black paint, and mounted it to the machine. \u00a0I used the aluminum bracket from the back of the Bomb Scope that came with the machine to slide my new mount into the Z-Axis slot. \u00a0Its just been sitting on a shelf since I got the machine, and for now at least I don’t have a good method for machining the angled slots needed to make my own. It looks good, but has a bit of flex, not an extremely rigid mount. \u00a0I will probably be remaking this out of aluminum one day, using this mount to machine the next one.<\/p>\n

\"spindle05-640x480\"<\/a><\/p>\n

After I got it on the machine, and clamped in the router, I noticed a small hair line crack spread as I tightened the clamping bolt. \u00a0 Arrrggggghhhh!!! \u00a0I will have to rethink my dimensions if I ever do build with MDF again. \u00a0For now I slathered on a nice thick layer of epoxy, and am calling it good. \u00a0I think it will hold up for a while at least \ud83d\ude09<\/p>\n

\"spindle04-640x480\"<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

Its time now to build a custom piece of hardware to mount the router to the OZO. \u00a0Research on the web indicated that people were using MDF for this kind of work. \u00a0Its dimensionally stable, and easy to machine, though the dust can be kind of toxic. I’ve never worked much with MDF before, preferring […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[3],"tags":[],"class_list":["post-392","post","type-post","status-publish","format-standard","hentry","category-ozorebuild"],"_links":{"self":[{"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=\/wp\/v2\/posts\/392","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=392"}],"version-history":[{"count":35,"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=\/wp\/v2\/posts\/392\/revisions"}],"predecessor-version":[{"id":438,"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=\/wp\/v2\/posts\/392\/revisions\/438"}],"wp:attachment":[{"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=392"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=392"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/soulysolar.mudventions.com\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=392"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}