Forum section: "Materials, techniques, processes and tools"?

[deVries]

The idea is to have one extra forum for general technology - all the items in the list... This would help to keep techniques from getting lost in vehicle specific forums.

+1 Another excellent idea by the genius Miles.

When you start the subject area, I suggest you do the first post in each topic. Why? Because you can then go back in later in the future to reference build threads (newer build threads) or specific posts that appear that reveal the best ideas or techniques, etc. That first post of yours for each topic could/should provide links to the best threads or posts you know of. So, it becomes "the sticky" for the thread. Of course, others can add more info, etc. as time goes on doing new posts after that initial 1st post of yours. But at least you will have that reserved space to edit & change as time goes on.

Great idea, Miles.

[MitchJi]

Hi,

The idea is to have one extra forum for general technology - all the items in the list... This would help to keep techniques from getting lost in vehicle specific forums.

What are we waiting for?

I could have used it (not a big deal) for this:
http://endless-sphere.com/forums/viewtopic.php?f=7&t=39447

heavy duty (50lb & 250lb) releasable-reusable nylon zip ties

[TylerDurden]

Let's kick off this new section with my self-serving question about cutting & machining aluminum:

I don't own a mill. I have a lathe, tablesaw, drillpress, bandsaw, jigsaws, routers, mitersaws and angle grinders.

I'd like to cut and dado 5/16" thick 6061 flat aluminum. One cut is 5/32" wide and one is 9/16".

I can send it to a shop or get a buddy to mill it... but if it can be done in a home shop, I'm game to try.

Doable?



p.s. I tried to upload a .stp file, but nogo.

[Miles]

p.s. I tried to upload a .stp file, but nogo.

Just rename the file as PDF or Zip it.

[Thud]

TD,
Your table saw will make that part in short order.
I would use a triple chip low angle blade & take several passes to work out the rough channel, then you can make a pass on the router table with carbde tiped bit for a nice finish.

The challange will be the .062"w grooves.....I would look for a thin kerf skillsaw blade (again in the table saw) & take shallow passes till you reach desired depth.

I will also recomend making some good push blocks as the alloy will generate some heat while is being cut. Save yourself a tense moment of hot fingertips in the middle of a pass.

So when are we going to see this new section Miles?

[Miles]

So when are we going to see this new section Miles?

Good to see everyone's keen..
Soon, hopefully... We're discussing it in the context of other changes.

[liveforphysics]

I'm excited for the new section.

[Miles]

Keep them coming. It's all useful ammo

[TylerDurden]

Thanks for the tips gents. I am revising the plan and I will post it in the new section when all is ready.

[Miles]

I've requested that .stp and .dxf be added to the file types accepted for upload.

[Miles]

.dxf and .stp file types now enabled for upload.

[TylerDurden]

Testing...



"The extension stp is not allowed."

[RWP]

Thank you Miles! I like this idea a lot.

Thud and I were recently reminiscing about the lost foam casting process. I think casting and casting processes are underrated here at ES and would love to see these and other areas Miles and others mentioned above get some airplay in a section of their own.

I have been around ES for several years now and have watched our evolution, with great interest. I noticed that something happened after the great betrayal and Justin's saving ES; some of us took a break. My break was around computer and health issues. No judgement here at all. So ideas and suggestions along these lines seem to me to be a good way to keep ES moving forward into it's next evolution.

Long live ES!

Roy

[Ypedal]

posted an update on the mod forum regarding the .stp files, it got added but something must not be set just right.. ( to anyone who's ever worked with phpbb ACP.. you know what i'm refering to.. )

[TylerDurden]

Testing...

EStrusion1.dxf

(772.89 KiB) Downloaded 22 times

[Thud]

hehe,
very nice.

[MitchJi]

Hi Tyler,

I don't own a mill. I have a lathe, tablesaw, drillpress, bandsaw, jigsaws, routers, mitersaws and angle grinders.

I'd like to cut and dado 5/16" thick 6061 flat aluminum. One cut is 5/32" wide and one is 9/16".

I can send it to a shop or get a buddy to mill it... but if it can be done in a home shop, I'm game to try.

Doable?

Definitely!

I think you could get good results using an Abrasive Saw Blade like this in a table saw or worm drive skill saw:
http://www.amazon.com/DEWALT-DW3511B5-Performance-Cutting-Abrasive/dp/B005B8LVUY/ref=sr_1_18?s=power-hand-tools&ie=UTF8&qid=1336704083&sr=1-18

DEWALT DW3511B5 7-Inch High Performance Metal Cutting Abrasive Saw Blades, 5-Pack
Price: $15.16

I got a pretty clean cut, using a blade like that with a worm drive skill saw. Two 6' cuts and one 4' cut.

Based on Thud's comments one of these should work even better (and cost a bit more):
http://www.lenoxtools.com/Pages/Product.aspx?productId=MetalCuttingCircularSawBlades

LENOX METAL CUTTING CIRCULAR SAW BLADES
A Faster Way to Cut Metal™

EXTENDED LIFE
Titanium carbide tipped
Resists material build-up on teeth

CLEAN, COOL CUTS
Less burr than abrasive blades
No need for secondary grinding
Reduces material burning

MODIFIED TRIPLE CHIP GRIND
For added durability

RESHARPENABLE

Aluminum - Copper - Brass

Code: Select all

Diameter
IN             MM    PROD NO          TOOTH COUNT    RPM
7-1/4        184    21882AL714060CT    60       5800    
10            254    21887AL100080CT    80        5200
12            305    21889AL120080CT     80        4000
14            355    21892AL140080CT     80        3000


Some choices:
http://www.amazon.com/s?ie=UTF8&rh=n%3A552292%2Cp_n_feature_browse-bin%3A387631011%2Cp_n_feature_keywords_browse-bin%3A2801548011&page=1#/ref=nb_sb_noss?url=node%3D552292&field-keywords=aluminum&rh=n%3A228013%2Cn%3A!468240%2Cn%3A328182011%2Cn%3A552262%2Cn%3A552286%2Cn%3A552292%2Ck%3Aaluminum

[TylerDurden]

Thanks, Mitch.


Testing .stp 214 upload...

"The extension stp is not allowed."

Still no joy.

[TylerDurden]

On the subject of tools, a new place has opened in southern MI:



$100/mo. (or $900/yr) membership provides access to shop, training & tools.
http://maker-works.com/

[Miles]

Test

edit: DXF seems to work ok. We're investigating why .stp files are rejected......

[Miles]

See: http://www.endless-sphere.com/forums/vi ... =1&t=39945

[MidnightRider]

maybe fixtures, or diy (best ones?)