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Scratch Build – In Progress Project - PowerCore

Discussion in 'Project Logs' started by riekmaharg2, 26 Jul 2020.

  1. Canardwc

    Canardwc @French_fab_factorie

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    What an INSANE welldoing WORK :jawdrop:
     
  2. Modultra

    Modultra What's a Dremel?

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    Nice work on the Bridgeport, way to make use of the tilting head. Mine is just a glorified drill press mostly, never actually used the tilting head. Did you just eyeball the z depth when cutting the angles? seems like every stepover would require a new z depth. knuckle roughing endmills are great, low cutter force and small chips. I use them whenever I can.
     
  3. Defyant Mods

    Defyant Mods Multimodder

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    Incredibly satisfying seeing that done to a chunk of alu :rock:
     
  4. riekmaharg2

    riekmaharg2 has started the PowerCore scratch build

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    Thanks everyone :grin:

    Yeah the bridgeports are incredibley usefull/versatile for manual work, yeah each step over was eyeballed on the Z axis, I very very slowly raised the table until I saw the finest of scratches from the milling bit, then locked it there.

    Sorry about the long wait, I dont no where the time goes these days, I blink and its been a week lol.

    I've milled off the sides and end of the back panel:

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    Then milled the hole for the power button:

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    I then sanded the panel down with an orbital sander but the forgot to take a pic of it before the next step.
    I rented a capacitor discharge Spot Welder from www.taylor-studwelding.com:

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    I couldnt get in to all the areas I needed threaded studs with the big gun, so I also rented this mini gun that goes into the end of the big one:
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    I then folder a bit of copy to prevent the earth clamps from putting dents into the alu:

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    I tried a few, then found the best technique was to press a blunt center punch into the alu to make a very shallow dent, that the little pip on the bottom of the stud just about sits into, then give it a quick sand:

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    I also spent hours marking out all these spots to put the studs onto, then welded them all on:

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    You get a fair amount of splatter, but it should come off in fine sand/bead blasting if I protect the threads. These are M3 threaded studs:

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    Next up I've started making the new water junction blocks of the outer coolant pipe section. I'm going to have to scrap the cast ones I did, since I found castings dont anodise very well, and colour wise your stuck with grey.

    I got a face mill as the old one was slightly bent and all the carbide bits didnt actually touch the work peice:
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    and then another three:
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    Works a treat :)

    Also got a new machine vise from RDG Tools, as the parts kept slipping with the old vise:

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    Also got a chamfering bit for the front edges:
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    I made 4 of these:
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    I then used the belt sander to curve the edges, I still need to finish it by hand sanding to match the chamfer:
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    These will fit in the case like so:

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    I should get these blocks completed this weekend.
     
  5. Cheapskate

    Cheapskate Insane? or just stupid?

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    NEAT! :D
    So that's what those weird studs are. I had a bunch of those in a big bucket of random bolts.
     
  6. riekmaharg2

    riekmaharg2 has started the PowerCore scratch build

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    Back for another update :)
    I've come to the conclusion that those DIYINHK DDC pwm coolant pump boards are crap, this thing is sooo loud now. I thought I had messed up somehow but after reading online it seems that these boards are just noisy af. Sooo I'm gonna have to get another acrylic piece CNC'd and use the standard control board I think.

    Anyway I finished off the bevelled edges on the new water junction blocks with a small file:

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    After tapping the holes, these are ready and waiting for the final surface finishing at the end of the build. I think I might chrome plate them:

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    I had to drill a hole all the way through from the side to connect all the holes, then I'll make some plugs to screw into the ends to seal off this side hole. The tapping was done straight after the drilling with the tap in the milling machine, and the gears in neutral so I could manually turn it, so as to get the tap dead centre.
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    I then spent most of this weekend milling out the bar mounts for each heatsink. Two of the mounts will also be the mounts for the back panel as well:

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    Wasn't great using the chuck for the 4mm ball end mill, but the collet has arrived now for next time :)
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    This weekend I'll mill the tops at an angle to fit the case.
     
  7. kim

    kim hardware addict

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    picture of beauty :naughty:
     
  8. ASPHIAX

    ASPHIAX Minimodder

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    Damn seeing all that milling work by you and cheaps makes me want to get my cnc from storage also. Truly awesome work. Cant get any more custom then this!
     
  9. Cheapskate

    Cheapskate Insane? or just stupid?

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    It's not normal to praise someone for making a bracket, but... :lol:
     

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