First, download the iso image. source, alternatively the mirror.

1.) unzip/copy md5sum.exe into the same folder/directory as emc2-ubuntu6.06-desktop-i386.iso
2.) in a dos window… type “md5sum emc2-ubuntu6.06-desktop-i386.iso” without quotes. This may take a few minutes.
3.) Compare the result to this “6ee5048eb9cb424aa030dfedccc5386b” without quotes.
4.) if they match, burn the image (google, howto burn an ISO image), and do verification at the end. If the numbers don’t match, you’ll have to redownload the image.
5.) Open the newly created CD, and you should see multiple files, and folders. If not, please see #4 and google.
6.) Boot off this CD. Make sure your bios looks at this CDrom as one of the boot devices.

Places to download md5sum.
http://etree.org/cgi-bin/counter.cgi/software/md5sum.exe
http://theopencd.sunsite.dk/md5sum.exe
http://www.fourmilab.ch/md5/md5.zip
http://downloads.activestate.com/contrib/md5sum/Windows/md5sum.exe

short explaination of md5sum.

SWEET!

So, the new project priority order is now:

1. Measure the backlash on the mill, all 3 axis
2. Mill out the Rotary Axis Bracket for the lathe
3. Limit switches for mill
4. Purchase:
   1. High precision/balanced Drill chuck, waiting on literature from Albrecht
   2. JT0 or JT1 to straight shank arbor, to use as spindle
   3. Small end mills (sub 1.0mm)
   4. Perhaps another Gecko G201 for the rotary axis. I may just use the mills power supply to do it instead. Much cheaper.
   5. Parallel bars
   6. ground 1-2-3 blocks
   7. V-blocks
   8. New clamping T-bolt kit
5. New Z-axis for mill
6. Egg art machine
7. Finish the electrical boxes for the power supply units.

As well as a confirmation of my work from before. The board I made for Damian works perfectly, as I suspected. Now I have to make either a new one for him, or another one for me. Fun.

The accuracy of the Z-axis is abysmal. Over 0.030″, the error is 0.002″ already. I will definitely either need to use EMC’s mapping feature (I actually have to look to see if that actually exists), or come up with the new Z-axis design quickly and effectively.

Luckily, the only things I need to actually mill out currently is going to be brackets, which are milled all the way through. No intricate workings right now. So that’s good.

Items of interested to make currently are:

• Poker Dealer, small and big blind markers.

Day 2 bore out a single hole.

Day 3 refine design
make a tool to hold the giant tap (1.302″ in shaft diameter to tap a 1-9/16″x18TPI hole)
tap the part.

Day 4 measure everything again
refine design
Mill out the part by hand (done horribly but works)
Disassemble mill
install newly machined bracket
reassemble mill.

Mill’s measurable backlash = 0.0005″ [on that axis]
I’m happy now.

What’s left now is to purchase some bolts, and machine the bracket.

Loads of fun. I wish I would just finish my axis issues in my mill.

Pictures to come on an update.

I’ve made a cardboard mockup of the part, but I couldn’t get really get any measurements off of the mockup. The cardboard kept flexing making it very difficult to position the secondary pieces to any acceptable limits. Another issue with cardboard is that it’s a soft material to measure.

Benefits of Acrylic over cardboard
1.) It’s ridged
2.) The variety I’m using is clear so I can measure bolt holes and such.

Downsides:
1.) much more expensive, as opposed to free
2.) Takes time to measure, score, snap, sand, assemble, glue.

So I guess I’ll try and use acrylic only when necessary — which this seems like one of those times.

Well, I didn’t measure most of the stuff I’ve been playing with lately, nothing bad has happened yet. I did have a mock up, so I cut by lining the mockup to the part.

What did happen is that I received two set screws from a local shop, and the package that it was taken out of said it was 6-32. Well, the set screws aren’t #6-32. But I have a nicely machined, tapped, and completed motor coupling that is ready for two new #6-32 x 3/16� setscrews. Even ¼� if need be.

Completed:

1. Spigot
2. Spindle
3. Spindle housing
4. Stepper Motor coupling
5. Motor mount spacers

To complete:

• Locking ring for spindle
  • bore it out
  • drill out holes
  • tap
• The mounting bracket now.
  • Machine the edges
  • Machine the spindle hole
  • Drill out bolt holes for motor mount.
  • Machine the bolt holes to mount the bracket to the spindle head.

To buy:

• #6-32 x 3/16â€? or ¼â€? length.
• Mounting bolts – measure what they are. I believe they are M8 x 1.25

However, I was able to cut myself, not on the machine, but by handling a part that I just cut.

It was a partial cut, where I could break the end by just twisting it… I snapped the part off where it was supposed to, but in the process I squished my finger, in the process cutting it.

To update

Completed:

1. The spindle
2. Spindle housing
3. Motor mount spacers

Todo:

1. Spiggot – Drill two holes at 90degrees apart and tap
2. Motor Coupling – Drill two holes at 90degrees apart and tap
3. Bracket
   1. drill mounting holes
   2. Clean edges on bracket
4. Buy proper sized bolts to bolt everything together.

I get distracted and misplace stuff in the mess all the time. I need some sort of tool management or something.

Anyways, progress on the Rotary-axis assembly is coming along nicely.

I’m thinking of using an angle bracket machined a bit to fit around the lathe spindle bearings, and weld a piece on the base to get a nice ridgid structure to mount the assembly. Photos to come. The cardboard mockup is embarrassing to show.
But carboard is your friend.

I’ll have to work on my welding skills [well, learn some welding skills].

More pictures with a nice background here,
here, and
here”.

It’s to make a rotational axis for my lathe. This is so I can do milling/engraving on cylindrical objects. Such as rings, and pendants. I can even use this to help rough out gears before hobbing them.

“Gear Hobbing” is the process of grinding/cutting out the teeth on a gear.

The spiggot machined. It was a pain to machine, but I felt pretty good when I was finished making it, as I machined it exactly to size. The error wasn’t measurable with the measuring tools that I have.

Spiggot for the worm is almost completed. I still need to put in the set screws for the lathe spindle shaft. All I need to do is drill two holes 90° apart, and tap them.

Worm Spindle, this part is the shaft that I needed to mount the worm to. It’s pretty precise; I think I’m about 0.01mm off from where I really wanted to be. But it shouldn’t affect anything, and well within tolerances of what I need it for. When I drilled the spring pin hole, I wasn’t exactly centered, so I drilled into the shoulder of the worm just a little. This shouldn’t affect anything as well. The spring pin was 1/16″, and had to be ground down, due to the pin and teeth on the worm gear were knocking. Out came the dremel clone.

It’s focus is designing useful spindles for small lathes, with the mindset of keeping it simple, easy to make, and low in part numbers.

It’s not bad in that aspect, and does cover the bases that I need to design and implement my own. I’m only using it as a reference for designs, and usage.

Hopefully in the near future I’ll make on.

Designs and renderings here