Upgraded 3018 Pro using MGN15H Linear Rails and a 500w Spindle

That looks Awesome, it's a shame you don't have a 220-240VAC version for AU/EU customers.

 

So I didn’t order a mounting plate for the z axis because I didn’t think I needed one (I was going to reuse my existing one). However, my current one doesn’t fit the bolt pattern of my 65mm CNC spindle mount for the Makita.

So I did what any respectable CNC owner would do, I designed and made my own.

I decided to try out the Maker Store DLC coated 1 Flute 3.1mm end mill on this, and it’s a beast! It leaves a nice surface finish too.

I do need to drill and tap the 4x M6 holes.

 

This mount plate came out really nice, I’m definitely getting better at making aluminum parts.

And I collected my Makita router this morning, it’s been used twice! The tradie I bought it from got the cordless version as he needed the flexibility to work without mains power.

 

My piece of 15mm 5083 arrived today, and and it's straight onto the CNC to be turned into mounts for the new Z-Axis.

 

Nooooooooo!

Stupid cheap Chinese spindle died with 2mm of milling to go! Looks like I need to visit the hardware store tomorrow for skinny chisel that’ll fit into a 3.1mm wide channel.

 

I realised that I can just drill a stack of holes and then dremel the rest out. It’s a good my other parts for this upgrade are finished.

In the meantime, I finished off my design for a 3D printed Relay and Power box for the Makita - It came out quite well, I think. The level lock terminal on the outside is for the relay to connect to my MKS DLC32 Spindle control. It’ll just be on off and should work well. For now, I’m just going to use the Dial on the Makita for speed control, however I might look into adding an RPM read-out to it, so I know what it’s set to.

 

Turns out it wasn't the spindle that died, it was the cheap Chinese 110vDC PSU. I might try to repair it, but I'm not sure I can be bothered atm (my new Z-axis is supposed to arrive today).

Anyway, thankfully, I was able to rescue my parts using my drill press and Dremel. Then it was just a matter of grinding off all the excess material with my bench grinder and wire wheel. Thankfully none of the surfaces that needed grinding down are required to be dimensionally accurate.

 

Hooray, my new Z-axis just arrived (soo sexy!). I mounted some MDF on the brick wall behind my gear so I could mount the relay box and also move the Controller off the machine too.

Now I just need to find some time to perform the upgrade!

 

I started work on the rebuild tonight, first the electronics got relocated to the wall and then I tore down the old z axis. I ran out of time to get any further than installing one of the z axis mounts - it does look really good, but I’m biased.

 

I spent half the morning avoiding work in my garage. Made some good progress on the rebuild.

My relay works perfectly too and boy does the Makita spin fast, I turned it up to it's max 30k rpm and wow! It's so well-balanced too, just no vibration at all. The new Z-axis is really rigid, if I try to flex it, it moves the entire machine and bench.

 

My Cable chain arrived today and it's really nice! It's the type with the flaps that open up to run cabling through. So I whipped up a mount in fusion 360 and it worked first go! I really should have started using cable chains ages ago, it really improves cable management! I do need to lengthen my Z stepper and end stop wiring - but I'll do that later.




EDIT: Left over Cable chain makes for great cable trays - I just drilled holes in them and mounted them to useful locations. I also replaced the solid compression coupler with a flexible disc style coupler, seeing as the Z axis uses a captive ball screw.

 

I recently designed a new dust shoe system based on the ideas Marius used for his system. It has the advantage of not moving up and down with the spindle as it’s fixed to the Z-axis mount.



So here’s my version - the side mounts will move up and down in the side of the 2080 and be fixed by a screw. The Shoe itself will attach magnetically to the sliding rails via 8 5mm neodymium magnets on each side.



The sliding rails will be 3D printed and the dust shoe will be CNC routed from 10mm thick, clear, acrylic.

I printed out my dust shoe design last night, and it turned out great first go. I had just enough bristle left for it and all I need to do is print out some knobs for the adjustment screws and trim the bristle brush down by about 20mm.


My acrylic sheet should arrive today, so I'll be able to make the clear insert this weekend.

 

I made a minor tweak to the sliding arms so they are easier to install and use - and I've now published my design:

Printables

My cad file is included for remixing.

Edit: I found some issues with the mounting arms in testing today that I need to find solutions for.

 

Ok, I think I have the dust shoe sorted. It’s not as effective at sucking up the dust as those on my previous spindle, but it still works well enough.

Oh and I kinda wrecked my bristle brush trying to shorten it with my angle grinder. so that won’t have helped. The other factor is the Makita blows directly down into the work surface to cool itself, so this means you prolly need a bigger shop vac than mine.

 

This Makita router is a beast! It just mows through acrylic @ 2,000mm/m, ~25k rpm and 1mm DoC. I must make something out of aluminium to try next.



The Clear sweeper insert came out really nicely, but this bristle insert is trashed (more holes than swiss cheese). I've got a new one coming tomorrow, which will hopefully help improve dust collection.

 

I really like the concept of the fixed dust shoe, but I decided I prefer my style of system from my previous spindle, where it sucks up the debris directly above the end-mill. I also found that the cooling air from the Makita reduced the effectiveness of my dust extraction.

So I went looking for something better - and I found a model I really liked, so I remixed it for my setup.

Printables

 

This turned out pretty well I think:


I’m waiting for some 12mm neodymium magnets before I can test it properly.

Honey, Just putting my hand under it while the vacuum is on was quite impressive, it think it’ll work really well.

 

Nice, I’ll prolly switch back to my fixed height version for milling aluminum. It’s pretty easy to switch between them.

I improved the arms on mine to make them a bit stiffer and easier to print. I do need to trim the bristles tho as they are too long.

 

No worries, I’ll dig up my files for you. I’ve been meaning to publish them too printables but haven’t gotten around to it.

 

Here you go:

Printables

 

I finally got back to my CNC project, I recently got an air blaster / mister - so I drilled and tapped some holes into the mounting bracket. I’m pretty happy with the result.

Then I finally got around to taking my spindle apart to install the relay and wiring for the GRBL_SPD controller.



Unfortunately, ran out of time to test it.

 

Cheers, nice relay board! I only used an SSR to power on my spindle as I had one lying around.

My current solution uses standard relays for control. I’m just in the process of rewiring everything and switching to inductive end stops.

 

It's actually illegal to do your own electrical work in Australia, unless you get it signed off on by a registered electrician.

 

Considering how stupid non technical ppl can be, I personally don’t think non certified ppl should be playing with 240v @ 15 amps.

ppl still do it themselves and if their house burns down from an electrical fault, their insurance company has every right to refuse coverage.

luckily for me I have multiple electricians in the family who will happily review and certify my work.