Machsupport Forum

General CNC Chat => Show"N"Tell ( Your Machines) => Topic started by: Sam on December 21, 2009, 11:05:06 PM

Title: Dixie Duke - A machine in the making.
Post by: Sam on December 21, 2009, 11:05:06 PM
Well, I suppose I'm going to build a mill this time. Might finish it, might not. Who knows. I'm not really that fond of commitments, since about '95.  :P
I'm not the best web page builder either, but it gets the job done. HERES (http://www.hillbillyhilton.com/dixie_duke/index.html) the link.

The original designers name is 'gmduke', and he graciously gave out his design, complete with prints and mcmaster part numbers for purchased items. Without his hard work, I would not be attempting this. Hence the machines name...Dixie Duke, in his honor. A post with his machine is HERE (http://www.machsupport.com/forum/index.php/topic,871.0.html)

HERE (http://www.cnczone.com/gallery/showgallery.php?cat=500&ppuser=46033) is his gallery on the zone.

Looks like his website is no more.
Title: Re: Dixie Duke - A machine in the making.
Post by: ostie01 on December 21, 2009, 11:11:34 PM
Look nice, look also like the Syil X6 or something like it.

Me too have some trouble finishing my project since for me, the fun part is designing the parts and machining.

Title: Re: Dixie Duke - A machine in the making.
Post by: RICH on December 22, 2009, 10:57:51 AM
Sam,
Post pics as the task progresses. We like pictures.
LOL for the Holiday's,
RICH
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on December 22, 2009, 12:05:50 PM
That's a good start Sam - looking forward to seeing further pics of your progress.

Tweakie.

btw. My wife sends her regards - she still remembers the Cheese Board incident.  ;D
Title: Re: Dixie Duke - A machine in the making.
Post by: BarryB on December 22, 2009, 01:06:32 PM
cool picts and renders.  i look forward to seeing progress;)
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on December 22, 2009, 06:00:55 PM
Quote
she still remembers the Cheese Board incident
Ahhhh, the cheese board. Who can forget that!  "C.B.I." as it's known to most. Yall haven't had the plague, have you? It's all because of the sacrifice!

Not much to report on today. 95% finished with the base part. I had estimated that part to take one day. I have 12 hours invested so far. I had to take a bit of care getting the rail slots just right. This was time well spent on such a critical feature. All I need to do now is the hole pattern for the rails, and tap all the holes. Then this part can go on the shelf. Next I want to do the saddle, as it will be the most difficult part of the whole build by far. I'm dreading it and looking forward to it, all at the same time. Anyhow, here's some pics. My cell phone dont take the best pics, but there good enough.



Title: Re: Dixie Duke - A machine in the making.
Post by: Chaoticone on December 22, 2009, 08:05:37 PM
Looking good Sam.

Brett
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on December 27, 2009, 10:19:31 AM
Very small update (http://www.hillbillyhilton.com/dixie_duke/html/dixie_duke-page_2.html)
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on December 31, 2009, 05:24:02 PM
Another small update. This is the saddle. Hopefully, I will get this part finished tomorrow. Other peoples projects are starting to take precedence over mine.  :(
Title: Re: Dixie Duke - A machine in the making.
Post by: RICH on January 01, 2010, 09:32:41 AM
Sam,
More work than meets the eye, as usual. Now you'll have more of an appreciation of the machines your using.  ;)
Same happens when i do a little model, takes just as long and then some.
At least your having fun,
RICH
Title: Re: Dixie Duke - A machine in the making.
Post by: Chaoticone on January 01, 2010, 01:41:00 PM
Yeah, what he said. And tell them we need our Dixie Duke.  ;D  They have to see it looks to good to be delayed.

Brett
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on January 01, 2010, 02:16:46 PM
HAHA! Hard to do when their waving cash in front of my eyes. I'll take all I can get right now.
Your correct Rich, it always takes longer than what was planned. Especially since the CNC mill took a bullet to the head. That REALLY put a damper on my project. Everything can still be done on the manual mill, but at a much greater expense of time. Discouraging to say the least.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on January 04, 2010, 02:02:45 AM
Just another update. Slow progress. More boring reading and additional pics on my site. I think I'm gonna go with a drilled and tapped table instead of a T-slot. At least I can see it taking shape now. Kind of like a fetus in the womb.  ;D  ;D  ;D
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on January 04, 2010, 03:03:38 AM
You certainly have done a lot of machining on that part - it's looking good.

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Dan13 on January 04, 2010, 09:01:00 AM
Good progress Sam. It's so rewarding to see the parts getting shape after all the hard work.

Keep up the good work.

Daniel

Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on January 04, 2010, 08:18:19 PM
Thanks for the compliments guys.
Yeah, I had allot more time than I had anticipated in that swiss cheese block. Manually peck drilling 2.5" (63.5mm) deep with a small bit and counter-boring 64 holes was quiet a chore. 'Fun' went out the window on that one. Roughly 16 hours in total on that part.
I got started on the table today. It's only surface ground so far, with one pocket cut in the bottom. Hopefully I will finish that part up tomorrow. It's got two 28" (711mm) long slots for the linear rail that I will have to take my time on to get right, and lots of mounting holes, so I will be lucky if I do get it done I suppose. Here's a pic of progress so far.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on January 08, 2010, 01:08:43 AM
Got the table 98% completed. All that's left is drilling/tapping some mounting holes in the top surface for vices and fixtures and such, and the end surfaces for the motor and screw mounts. I did manage to slap it all together and give it a test slide. Everything is really nice and smooth, and feels very solid. I'm a happy camper so far. Next up will be the column, or the cabinet its all going to sit on. I haven't finished with the design of the cabinet, so most likely will start on the column. HERE (http://www.hillbillyhilton.com/vid/movement.wmv) is a crude video of it sliding.
Title: Re: Dixie Duke - A machine in the making.
Post by: Dan13 on January 08, 2010, 01:28:31 AM
Looks fun playing with the table... ;)

Daniel
Title: Re: Dixie Duke - A machine in the making.
Post by: Overloaded on January 08, 2010, 07:31:04 AM
VERY nice work Sam...this stout little beast should perform well.
A good compromise on size, the mobility is a plus too.
RC :)
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on January 08, 2010, 12:49:40 PM
Thanks RC. Definitely had to be mobile. Pretty much every machine and work table I have is on casters, and I don't see how I would get by without them, now. There a really good feature to have in a crowded shop.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on January 23, 2010, 08:38:43 PM
Small update. It's been a couple weeks since I have had time to work on it. Started on the column today. Still have to surface grind and mill some pockets in it. Quiet a bit more to do to it until this part is ready to bolt on.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on February 05, 2010, 08:39:19 PM
Slow progress, but progress none the less. Finished the column today.
Title: Re: Dixie Duke - A machine in the making.
Post by: Overloaded on February 05, 2010, 11:46:02 PM
Looks real good so far Sam.
Keep up the good work.
Looking forward to seeing it finished and running.
Again...NICE !
Russ
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on February 06, 2010, 02:26:01 AM
Thanks for the kind words, Russ.
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on February 06, 2010, 05:39:05 AM
Right on Sam - that's going to be some machine when it's complete.
Keep posting the pics of your progress with this one as I never got to see the final build pics of your router.

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on February 06, 2010, 10:37:35 AM
Thanks Tweakie. Here's the router... http://www.machsupport.com/forum/index.php/topic,6139.0.html

Not really a top quality build, but it works pretty well. Ignore the cheap chair wheels. They were only for painting, then replaced with a good set of casters.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on February 10, 2010, 01:31:44 AM
More progress. Finished the Z motor mount, counterweight sprocket attachment, and motor spacer. I intended to anodize the spacer, but in my haste to get the ano tank set up in a freezing shop, something went wrong and the part came out bad, so that's a bummer. Oh well, I'll take function over fashion any day of the week.
Title: Re: Dixie Duke - A machine in the making.
Post by: Chaoticone on February 10, 2010, 06:25:15 PM
Looking good Sam. That will have to make a sweet machine.

Brett
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on February 11, 2010, 12:22:05 AM
I sure hope it turns out well, Brett.

So I took my spacer out of the dye bath, and I was not amused at all. It looked worse than what I had imagined. So I guess a bit of fashion might be a good thing after all. I hate stripping anodizing off. Sandpaper is made with aluminum oxide (most sandpaper), which just so happens to be what the ano layer is. It's like trying to cut a stick of wood with another stick of wood. Anyhow, it had to be done. I've spent way to much time on the machine to take a shortcut now and ugly it up. I decided to change the color to an acid wash, too. I done some bike parts like that, and they turned out really nice, so I figured what the heck.
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on February 11, 2010, 02:18:01 AM
Very neat Sam - Keep up the good work.

Thanks for the link to the router pics - Nice machine you built there too.

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: budman68 on February 11, 2010, 09:11:19 AM
Looking great, Sam, fantastic work-

Dave
Title: Re: Dixie Duke - A machine in the making.
Post by: Chaoticone on February 11, 2010, 05:05:53 PM
Dang Sam................... that looks real good. True to form for Dixie Duke.

Brett
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on July 30, 2010, 06:05:49 PM
Well, I had a bit of time to work on the mill today, so here's a small update. I installed the rails on the column for the Z axis.
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on July 31, 2010, 01:23:00 AM
Excellent Sam, glad to see some more progress on the Duke.

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: budman68 on July 31, 2010, 07:33:48 AM
Nice.....and no movement of the material after it was slotted?

That's going to be slick machine -  ;)
Dave
Title: Re: Dixie Duke - A machine in the making.
Post by: RICH on July 31, 2010, 07:48:43 AM
Your getting there Sam, be making chips before you know it.
Keep posting pics.
RICH
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on July 31, 2010, 09:55:10 AM
Thanks for the compliments guys. I had to blow the dust and spiderwebs off of it, because it had been sitting there so long.
Quote
and no movement of the material after it was slotted?
You mean from the release of any stresses caused by the slotting? Na...If it did move any, it would be such an insignificant amount to not be of any concern. There only .135 (3.43mm) deep, and there close enough to the edge, where there is added rigidity from the side walls.
Title: Re: Dixie Duke - A machine in the making.
Post by: Overloaded on July 31, 2010, 03:58:26 PM
 :)
Happy to see you back at it Sam......anxious to see it done.
I am envious of your dedication, even with a well deserved break on occasion.
All in good time, like good wine.
Thanks,
Russ
 :)
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on July 31, 2010, 04:43:36 PM
Thanks Russ. I don't think the word "dedication" has EVER been in a sentence describing me. Probably never will again, either.  8) I'll be glad to see it done also. Ball screws shipped out today, casters shipped out today, I have the spindle motor and VFD already, I'm hopefully going to build the cabinet stand this weekend, and I'm going to try my luck at making a spindle this weekend or Monday. That may be to much at once on my plate for 2 days, but I'm going to make an effort at it, anyhow.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on August 05, 2010, 06:35:02 PM
Scratch one more "to do" off the list. What a pain in the butt this was. I'm glad to get it done...finally. It's out about .0002-.0003, but that will more than satisfy me. Not bad for a first attempt. I know you guys won't believe me if I said I made it in a 3 jaw chuck, so I'll just keep that to myself.  ;D
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on August 08, 2010, 06:53:54 PM
X & Y screws mounted. Scratch one more "to-do" off the list.
Title: Re: Dixie Duke - A machine in the making.
Post by: budman68 on August 08, 2010, 07:01:11 PM
Really nice!!!
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on August 09, 2010, 01:58:15 AM
Great work Sam - at this rate it will be making chips in two weeks   ;)

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on August 09, 2010, 06:01:55 PM
Yep, If I could have 2 whole weeks to work on nothing but Dixie, it might be possible. Unfortunately, I don't see "Dixie chips" (hey, that's got a nice ring to it :) ) in my 2 week future.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on August 20, 2010, 12:34:57 PM
A bit more done. I think all I lack now is making motor mounts, then I can temporarily hook up the electronics, to see some movement. Man, that head is HEAVY. Gonna hafta find a source for some lead shot to make a counterweight. 150+ Lbs I would reckon.
Title: Re: Dixie Duke - A machine in the making.
Post by: Overloaded on August 20, 2010, 05:10:12 PM
"Dixie Chippin' " might not be in two weeks.......but it sure won't be as long as it has been !
Looking real good there Sam !
The mass and rigidity will definitely work to your advantage.
I like it !
Russ
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on August 21, 2010, 05:23:47 AM
That machine has virtually been milled out of the solid.  ;D

Nice work Sam.

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on August 30, 2010, 02:30:41 PM
Yep, pretty much! It's been one billet machined after another. Finally got 2 motor mounts made this weekend. I'll be glad to see some movement soon... I hope. All this work being done, and it seems like there's no real progress. I need to see something function, #@&%$! Next up is making the mount for the spindle motor. Gonna hafta do some cad work before I can start on that, though. Fitting that large of a motor on such a small space is proving to be a challenge, to say the least.
More pics, but unfortunately no video yet.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on September 07, 2010, 06:09:38 PM
Still no chips yet, but more progress. Made the stand (well, part of it), and attached the spindle motor. The stand will house all the electrical, and coolant tank. Will probably have drawers or shelves too, for storage. There will be four more vertical post, (2 front, 2 rear) giving more support, and dividing the electrical, coolant, and storage compartments. I ran out of material, so it just didn't get done this time around. Took a short video of the roadrunner/coyote code running. I bumped the feed up 200 ipm. I tried it maxed out at 270ipm@45,000hz, with the acceleration maxed out, but the gecko's didn't like that. >:D With the acceleration tweaked, 300+ ipm would not be hard to achieve at all. That's about 200 ipm more than what I need, or want, and at the first sign not having enough torque, I'll be incorporating a drive reduction. The Z axis motor did not seem to show any weakness at all lifting the 130 pound head at 200 IPM. I was quiet shocked at that. Still gotta find me a good (cheap) source for some lead shot to make a counterbalance. All in due time, I suppose. http://www.hillbillyhilton.com/vid/DDvid.wmv
Title: Re: Dixie Duke - A machine in the making.
Post by: budman68 on September 07, 2010, 06:19:06 PM
So very impressive, Sam, just beautiful work.

Dave
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on September 29, 2010, 08:40:12 PM
Thanks Dave.  ;D

Finally got it home in the shop, and the basics wired up. Still gotta put the limit switches on, chip pans, make an enclosure, and put some panels around the cabinet. Still need to purchase a few items, like a coolant pump, hoses, lighting, switches, knobs, and the list goes on and on. At least I'm able to see it make some chips. I'm really impressed the most with the spindle. It runs really smooth and quiet (knock on wood) so far. Hopefully nothing drastic will go wrong. If it last for a few hundred hours, I'll be one very happy camper! For less than $100, 8) and whatever time I spent making it, I certainly can't complain! There does not seem to be any noticeable end-play (yet). Maybe next up will be one with a quick release (drool). First I'm gonna see how long this one last, though. I made a few cuts .04" deep with a small fly cutter across a 2.5" piece of aluminum, and it would have taken more with a larger cutter, but I do hate those darn cutters. There brutal on bearings. I gotta get me a shell cutter (add that to the list). I snapped this pic of a .01" pass with a fly cutter. Looks to be a nice, even finish all the way across. Very pleased so far.
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on September 30, 2010, 01:59:03 AM
Smoooothhh.  ;D

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Cosha on March 29, 2011, 03:39:25 AM
Looking forward to an update of this beauty - its been 7 month almost!
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on March 29, 2011, 08:34:23 AM
Not much to update as of yet, I'm afraid. The winter months sure do slow everything down. Right now everything is disassembled, and awaiting a good warm couple days that will allow me to paint it.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on April 03, 2011, 09:19:30 PM
Fabricated the chip pans and coolant return and welded all that together. Coolant tank delivery shouldn't be far off. Finally got it painted before it rusted into a heap of oxide dust, too. I used an industrial epoxy, so when it finally cures, it should be hard as rock. All that took about 20-30 hours. Next I have to rewire everything completely. Enclosure is purchased, I just have to lay everything out on the back panel and start mounting components. Part of the weekend also consisted of replacing components on a speed control board for the spindle. I fried it by hooking up the input power in reverse. Just as a "heads up" to whom it may concern....the white stripe on a 'wall-wart' power supply cord, does NOT always indicate it's the ground. Live and learn. I still wanna smack somebody over that one.
Title: Re: Dixie Duke - A machine in the making.
Post by: Dan13 on April 04, 2011, 01:50:54 AM
Nice, Sam!

Tell me something, how do you plan to make the coolant flow from the right side of the tray to the left side where the drain appears to be? My F1 sits the same way in the middle of the tray and I don't know where to do the drain and how to make the coolant flow there.

Dan
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on April 04, 2011, 01:59:52 AM
There is a tube underneath connecting the two sides. You could use a hose or whatever, I just welded a tube at a slight angle to join the two.
Title: Re: Dixie Duke - A machine in the making.
Post by: Dan13 on April 04, 2011, 02:03:45 AM
OK. Thanks. The way the F1 is, I think I will not be able to connect the two sides. I think the only way is doing two drains, one on each side, and interconnecting them underneath.

Dan
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on April 04, 2011, 02:12:53 AM
Looking good Sam, in fact looks like a real mean machine now.  ;D

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on April 22, 2012, 09:54:32 PM
Well, it's been a while since I have shared anything, so I snapped a few pictures of my latest project. It is an alternator bracket that needed to be redesigned in order to shift the alternator an inch or so. It was currently to close to the turbocharger, and the fear was that the heat would get the better of the alternator unless moved. As far as the machine goes, it has been making chips pretty much on a daily basis. It reeeealy needs some way covers, and the limit switches installed, and the coolant pump hooked up, and fully enclosed, and......well the list goes on. I think the next thing to do will be to make another set of motor/spindle pulleys, to accommodate two belts. It starts slipping when you try to take a good cut, and of course that usually means a broken cutter. Anyhow....
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on April 22, 2012, 09:56:05 PM
more....
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on April 23, 2012, 01:27:43 AM
Nice work Sam. Truly a machine to be proud of.

Tweakie.
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on April 23, 2012, 03:54:49 PM
Thank you Tweakie. Now I need a laser machine to mark the parts with :)
Title: Re: Dixie Duke - A machine in the making.
Post by: ostie01 on April 23, 2012, 04:29:03 PM
I know someone in UK that could do it for free ;D ;D

Jeff
Title: Re: Dixie Duke - A machine in the making.
Post by: Sam on April 23, 2012, 04:40:47 PM
I know that same person. I'm not so sure about the "free" part, though. I mean, I would have to charge him something for his time and effort.  ;D
Title: Re: Dixie Duke - A machine in the making.
Post by: ostie01 on April 23, 2012, 10:20:02 PM
I'm sure he could engrave a pretty women on your part ;D ;D

Jeff
Title: Re: Dixie Duke - A machine in the making.
Post by: Tweakie.CNC on April 24, 2012, 01:48:09 AM
 ;D ;D ;D

Tweakie.