Had a good day with Derek and Chris Sunday. Made some ugly parts and learned some interesting things. I now have first-hand appreciation for Ron's advice about not bothering to fine-tune the machine to 0.001" until we get the slop out.
I was cutting e-chain with a 1/8" bit. There are some 1/8" channels cut in the design for tabs and slots. I found in practical use that we have about 1/8" of slop, meaning two slots might be aligned, off-center, or completely divorced from each other, depending on the mood of the machine! ARgh!
So we need to shake down the mechanicals. I have a suspicion the bulk of the play is in the z-axis rails. I'll bring a dial indicator next time to confirm that next time.
I tightened up the z-slide eccentric bearings as much as they would go...which is NOT very much. I'd guess they have an adjustment range of maybe 0.050" (~ 1/16"). This was not adequate to tighten it up.
If I'm really on the ball, I'll cut new rails before I come down next time. The first time, I profiled the edge of the angle iron to mate with the v-bearings. Folks on Joe's forum says it's not necessary...but when you have a mill, everything looks like a nail. Anyway, I'll leave the next set as-is.
Derek fashioned a box around the router as a prototype dust shield. Hard to quantify, but it contained the majority of dust and vacuum, allowing the dust collector to do its job. It caught maybe 80% of the dust, compared to 25% before? It is a rough proto, to be followed up with something more substantial. Alternately, we could just buy a professional dust shoe for $140 from
http://www.kentcnc.net/nc/products/94-standard-dust-shoe.aspx , something like this:
http://www.youtube.com/watch?v=KwJtPmGrg-E Opinions?
As it is, the machine is fine for large-scale, low-precision work: signs, adjustable parts, etc. Especially in soft media, like foam.
Well, off to bed now...
-dave