BMW V8 dry sump from billet

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Jasonb:

--- Quote ---One thing I haven't considered yet... is how I'm going to stop the bit I'm cutting off from falling away as I finish the slots off. I can see me losing a cutter very easily in that scenario.

--- End quote ---

Leave a small section at each end and then saw it off by hand

Parafin is a good cutting fluid for ali.

Jason

No1_sonuk:
Cut through at each end before the middle and tie a rope on it.

AdeV:
Another thing I need to consider; as I get close to the final cuts, the end pieces will start sagging down, which is not desirable I think. Dad suggested putting some plywood underneath the entire piece, so the entire disc is supported. I think that's a pretty good idea, any views from the panel?

So, on to tonight's work... just more slotting, really. First job was to complete this slot from yesterday:

Nothing exciting happened, I used WD40 as coolant (the paraffin is reserved for the space heater!), the slot was completed & the disc rotated to pick up the next slot.Having lined the billet up, I need a reference for when I come to mill out the other side. So; pick a suitable spot & spot-drill:

Then drill through (in hindsight, I should probably have left the drill holes blind for the time being, as all the WD40 dripped out of the holes - so I used lots more than I should have!):

So now, when I turn the disk over, I've got 2 holes which I can draw a line between on the backside, which will exactly match the slot on the front side.

Finally, mill out to the desired depth. Which, in this case, is absolutely as far as I dare go:

I started that slot with what was left of the old cutter (since it broke half way up the shank). I pushed it hard and fast and dry, until it snapped again - this time in the flutes. But it managed 0.600" - nearly half way down the slot. I loaded up the second cutter, and carried on with a bit less pace. No more photos, nothing exciting happened.

Next - rotate the disk again & make another slot (last one). Here it is after the first 0.200" pass:

Swarf-tastic. I managed one more cut (to 0.400") before I called it a night; the bearing on top of the mill is starting to get hot, so tomorrow's first job is to whip the top off the bearing housing & re-pack it with grease. This is the same bearing that seized when I first had the mill, and it could really do with being replaced - but I don't know how... does anyone have a how-to, by any chance?

kvom:
If it had been me, I'd have used a much bigger cutter. My 5/8" endmill can easily take 1/4" deep cuts and could full depth. Power feed on the x-axis is a big help too. Your way is working though, so who can complain? :beer:

Bernd:

--- Quote from: AdeV on February 10, 2010, 04:41:51 PM ---Swarf-tastic. I managed one more cut (to 0.400") before I called it a night; the bearing on top of the mill is starting to get hot, so tomorrow's first job is to whip the top off the bearing housing & re-pack it with grease. This is the same bearing that seized when I first had the mill, and it could really do with being replaced - but I don't know how... does anyone have a how-to, by any chance?

--- End quote ---

Here's a link to a post on how I fixed my fine down feed. There may be something in the pics that'll help. Unfortunatley my machine has variable speed and is much flater on top so I could do it the way I show in the pics. But you may pic up something on how ro take it apart. Fine feed fix

Bernd

Did a quick google and came up with something that might help. Bridgeport Parts

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