I know nothing about CNC, so I bought a 25 year old Milling Machine
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- čas přidán 16. 01. 2024
- Hey! Been a while! I bought an old milling machine. I also bought an old bandsaw. I work on both and kind of make a part on a CNC machine, as well as talk about metal 3d Printing. I'm learning.
And as always, My social media:
Instagram: / wesleykagan
Website: www.wesleykagan.com
Metal 3D Printing: Changed things around, Please reach out on my personal website linked above.
If you'd like to support the channel, You can do it here. Times are weird, Please don't feel obligated. I hopefully have merch coming soon. wesleykagan.com/checkout/dona... - Auta a dopravní prostředky
Thanks for watching! A few things I wanted to mention: I am more active over on Instagram @wesleykagan, believe it or not I don't just awake from a deep slumber and upload a video (although that sounds nice.) Also! I'm putting together an intake/M120 parts kit that I'll have up soon. For right now, I have the M120 V12 exhaust flanges for sale linked in this comment. Think of it like merch that you can weld on? Not sure. Racecar video soon!
Exhaust flanges: www.wk-printing.com/shop/p/mercedes-m120-exhaust-flanges
Edit: Oh yeah, sorry about mid-roll ads. I might pull them, but I’m trying them out here. I personally hate them, but.
" believe it or not I don't just awake from a deep slumber and upload a video"... I'm immediately reminded of those videos of dogs running in their sleep who wake up, and continue running... straight into a wall 😅
"Wesley Dreams of Fabrication?"
Awesome to see you back here, I'm excited to see your instagram teasers converted into video form here!!
Soooo if you want someone to bounce ideas off and ask questions too, I’d be willing to offer my 15+ years of 5axis cnc prototyping experience. I’ve done inspection and CMM work as well as manual and cnc lathe, including live tooling.
If you’re interested, I can give you my Google voice number.
id love to see a video of you upgreading this to a masso g3 touch cnc controller, i hate these old controllers on 90' machines and this would lauch the cnc into the 21. century
i dint know if you would need that , but it would be really 😎
The ads are good because i learnt something.
@@moron_with_a_voron Honeslty though, those old fadal controls are kinda fine. But I get what you mean, you could have so much more storage and be able to have a conversational mode.
don't force yourself to upload on a schedule, I'd rather have infrequent uploads with good quality and progression.
That’s where I’m at- I’d like 1 video a month, but I’m at the point I’m only going to post stuff that I’m happy with.
You owe us nothing. Work at a sustainable peace. 😇
Exactly this ❤
yeah, id rather have it random, than get some wack video once a week
All my favorite channels don’t upload on a schedule, just upload stuff when it’s ready. Doesn’t matter if it’s a minute or an hour
Old industrial kit like this is great because they're often just cobbled together from off-the-shelf computers inside, meaning parts are still available, although any custom software won't be.
I can order 90% of this machine from McMaster Carr, it’s really nice.
And a lot of homebrew software is around for modding old gear too.
Our hackspace recently acquired a 1980s Bridgeport Interact 2, all the power systems are your typical industrial fare, but the control system is utterly bizarre. There's a big Heidenhain HMI with a beautiful orange CRT and horrible UI that communicates with a black box semi-custom PLC which controls three weird, esoteric DC servo drives via a 0-10V analogue control scheme that no other drive seems to support, and naturally one blew up. I keep joking we should replace the whole lot with an Arduino Uno running GRBL...
@@joeofloath Literally do it (though use some Linux CNC Mesa Boards) I'm going to be doing that to my Bridgeport Series 1 Interact :P
Fadal is kind of unique in this respect actually. They were a parts bin machine to begin with, and there were so many of them sold that it created a strong aftermarket for parts. Ten years ago you could still easily order pretty much anything likely to need replacing, not sure if that's still true now. If you blow a drive or control board on Matsuura or something, salvage spares can cost $$$ if you can find them and if not you're stuck trying to repair yours. Doing a LinuxCNC conversion is an option but is a pretty complex and time-intensive operation on a VMC with ATC versus a CNC knee mill.
As someone with decades being in factories and from Michigan, I am glad to see an old Kalamazoo saw restored and used.
I’ll take some heavy built American tooling any day.
Yeah its fun seeing the town you live in in a video like this
That hand bandsaw was for the birds. Floor band saw is where it is at.
My first real job as a kid was in a machine shop, and i swear this might be the exact machine the CNC guys had lol. Brings back memories, we would make all kinds of parts.... i would help debur parts until 12 oclock then take off in the work van and delivery parts the rest of the day. Roll up a few joints put on the rock station and hit the road lol, man time really does fly.
As a fan of Project Binky, I'm quite used to gaps in between uploads. With the quality of content you provide, its totally worth the wait!
if you follow enough channels that post sporadically, youll eventually have a new video every day from at least someone 😄
Dude he would take months between uploads at times lol I followed it for years and eventually gave up
There are fans of project blinky? Wonders never cease. Drawing comparison from those clowns to this guy is insulting to this guy.
@@fredio54what's your issue with BOM? Theyre great guys and a wealth of knowledge
@@fredio54 what are you talking about? The guys in blinky are insanely talented fabricators. Man, really showing your ignorance with that comment
Looks like Wesley lost quite some weight! Good on you!
I noticed that also👍
Hell yeah nice to see you back making videos. Btw great job on the weight loss, looking great!
Thanks! Yeah 60 less pounds is nice!
I found his weight it’s not fair take it back
@@WesleyKaganWay to go, buddy! I was thinking you looked a lot leaner!
Mate I was a machinist for years and I was really impressed with what you machined up, having never used a CNC before. 10 out of 10 my man. Good rule of thumb is
Turning: Big cuts slow feed. (0.004” per rev)
Milling: small cuts fast feed. (0.004”-0.008” per tooth) though be careful with smaller cutters.
When finishing up the speed by 25% and slow the feed by 50%.
Again this is only a rule of thumb…suck it and see. 😉👍🏻
Great job on the band saw too. Looking forward to seeing the next video. Subscribed 👍🏻
…Oh and at last a Yank that uses the proper term “Thou” as opposed to “Thousandths” I’m impressed..😁
Blessings from England. 😎👍🏻
Thanks for this Rule of Thumb....... really nice one to have in mind
Small tip for accurate bolted fixtures: use 2 pins for positioning, along with the bolts for keeping it in place. It's probably not needed for 90% of the jobs, but very handy on those few that need the positional accuracy.
Good point- could’ve used alignment dowels instead. I’m kinda curious now on if the misalignment would come from the hole being twist drilled and not reamed, or the bolt itself. Either way, on a critical part, I completely agree.
@@WesleyKagan Most of the misalignment will come from the loose fit of the bolt in the hole and the non-precision of a threaded surface. Never rely on a thread for accurate positioning.
Expanding arbor pins are good too. You can align and hold the part in many cases
@@WesleyKagan the misalignment comes from the play in the bolts.. they dont slip through bolt holes snug so there is positional play in your x.y axis... you can rotate the part slightly even with all the bolts in place..the dowels into reamed holes on fixtues eliminates that play
Definitely pick up an old used copy of Machinery's Handbook. Takes much of the guesswork out of setting up machine tools.
Also, if you're going to re-register parts like that, you should have some alignment dowels in the corners of your stock. Grab a package of 1/4" dowel pins and a 1/4" over/under reamer set for just that purpose. Ream your fixture undersize, press the pins in, and ream your stock oversized for a close sliding fit. Obviously for this part it was primarily cosmetic, but if you need precision between setups, this is the way to go.
Noted- thanks for the tip! Alignment dowels seem to be the way to go. Honestly trying to hold onto these thin parts is half the battle, excited to make an actual part!
Will do on the machinery handbook. Thanks!
Holding thin parts is made easier by using a Venturi system to hold the part down. It only works if you have a low weight to surface area.
It works by removing the air from under the part and in turn allows the atmospheric pressure to hold the part down. So if you calculated your surface area of the part, then multiply it by 1bar, you’ll find out your hold down force.
I regularly work on, repair, and maintain these Fadals through my job if you need any tips. @@WesleyKagan
@@WesleyKagan : I have a copy of Machinery's Handbook here... there's not much CNC info in it.
1948 edition! 😜
@@WesleyKagan : What I don't understand is how you found the courage to hit "Start"! 😰
It is so pleasing to see a young lad restoring old machinery! Thank you for the great vid!!!
Glad you enjoyed it
The chatter is the plate being very thin more than anything, for a face mill finish pass I would recommend about .008" depth axially and about 0.004" to 0.002" feed per tooth if you're shooting for a very low surface roughness. If you up the spindle speed without the feed rate you also reduce the chip load per tooth which reduced the cutting force. Sometimes though parts actually need you to lean on them a bit to take the flex out of the system. In this case however I would aim for a light cut and try to avoid a spindle speed that has a harmonic in the setup/machine.
Those are two spectacular additions to the shop. Congratulations on making them run as good as they do! The display on the CNC machine made an impressive difference :D
Thank you!
totally agree....never new you could even do that slick replacement....now to find a used Fadal :P
Wesley, your videos are smart, educative, and fun. keep it up
Thanks, will do!
Wow! What a video. So happy to see old equipment brought back to life. The band saw was a really nice extra that came as a total surprise. Good luck with upcoming projects! I'm eager to see what you'll come up with.
Oh a new episode of Hand Tool Rescue!
Both of these came out great, i can't wait to see what you create with your new cnc machine and that bandsaw looks fantastic
Hi 👋, great job. Great to see old machinery coming back to life., I am now retired in my 70s years young, I still have quite a lot of my tools and machinery, I’m a specialist joiner cabinet maker by trade my own business back in the UK, over the years, I have brought and rebuilt a old planer made by dominion, I had to get some components re-machined for it to work accurately, in some respect, it is a lot better than what you can get nowadays as it is a solid cast-iron machine, I have a Wadkin RS8 wood lathe, that I have rebuilt, with a VFD driver, single phase to 3 phase inverter, And I have a Wadkin EKA Tenoner machine , both of which date back to the late 40s, early 50s, to buy anything, equivalent, strength and reliability, nowadays, would cost you an absolute fortune, I look forward to seeing some more of your work, And I’m a great fan of Steve Morris, engineering, I think just recently he had a new machine secondhand machine fitted multi axis milling machine,
That machine brings back memories. My dad owned a Fadal for his aerospace machining company. It was a fantastic unit. Good luck on using it well.
Thanks! So far it’s much better at its job than I am.
Just to share my Dad retired at 80 in 2003. I spent many a Summer helping supervise the Fadal, typing programs on paper punch tape and such. My Dad was a world class machinist getting thin walled aluminum wave guides into a generation of satellites like Telstra. He used a lot of tricks, built jigs a lot and employed a dead blow hammer to solve some of the things you alluded to in the video. You will figure it out and thanks again for the trip down memory lane
Very nice, thanks for sharing!
Thanks for sharing the journey. Your dry sense of humor keeps me coming back - even after 9 months. Looking forward to the next one.
Thanks for giving old equipment a new life. As someone who is old equipment it makes me feel a little less worthless. Cheers!
You're not actually limited in the 3D metal printer, you just have to weld the bits, which implies you need to design them to slot into one another. There's a group out there that 3D printed an entire car front frame.
the car they made killed twelve of their team though.
@@amandahugankiss4110what
So glad to see another upload from you! I've been wondering what happened to this channel lately
I’m back! I’m around, I just have a lot of half finished projects haha
I am extremelly glad to see you seem to be doing well. Congrats on the machines!
So many new uploads from channels I'm subscribed to despite not getting anything new for months or even years. From all different genres, too. Loving it.
Great work all round , I have been through trials with a bandsaw and a CNC and my 3d printer! Loving the videos cannot wait to see more on the V12 , thank you for getting a video out, ❤
I've never tried it, but I heard ZEP oven cleaner works super well for cleaning up these old machines
It should work okay. Soluble oil creates a weird film that can be hard to remove over large areas. It may seem easy enough to clean at first but then you see how big the machine is vs the 1sqare yard you spent an hour on. Weirdly, or perhaps just logically this film comes off pretty easy with... More soluble oil. Newer machine coolants are less prone to separating and leaving waxy films. They also often smell minty fresh and don't have problems growing nasty stuff in the coolant tanks. No more chlorine tablets or oxygenating bubbly things for machines that stagnate. An active machine will oxygenate the coolant as it runs but for shops that only use these things a couple times a year the new coolants are a game changer over plane old soluble oil.
Please post more
Trying to, I’m going to get better. One video a month is the goal right now!
@WesleyKagan nah, post whenever works. I'm here bcs of how good the content is. People like you and Micheal Reeves have a following based on quality, not quantity.
@@WesleyKagan.
One a month, I’ll take it 🤝
Good to see you back - look forward to your next video, I find them worth the wait 👍😁
Thanks for giving life to old beat up machines! I love the paint job!
I was wondering where you went after you didn't post for 24 hours.
I know, and the 24 hours after that I’m sure was a real nail biter
@@WesleyKaganI don't have any nails left at this point. Had to run down to true value to get some more
Set the tool heights from the bed, then just use the distance from that (top of the tool gauge) to the work piece as your work offset (G54 z value).
This will mean you don't have to reset all your tool length every job.
Keep going! Very jealous.
Yeah, I tried that starting out- The issue I ran into is that my post processor likes to send the machine to E1 + T1 tool offset, which then trips my z axis up. Still working on how to feed it Gcode that it likes.
@@WesleyKagan Oh Z's inachine coordinates are weird, all negatives. keep going, I've spent way too much time talking to an LCD panel (well crt to begin with, I could smell the inside of that panel when you opened it) questioning it's actions😁
An old CAD teacher once said "if you do a job, got paid and the customer was happy. You did it right". If you are your own customer, win all round👍
STILL MUST MEASURE DO THE OFFSET BECAUSE THE HEIGHTS OF EACH TOOL STICKS OUT OF THE TOOL HOLDER AT DIFFERING LENGTHS ALL AND ALL NOT MUCH DIFFERENCE
I'm impressed. You did really well for your first time on that Fadal. I have a 4020A in my shop and a series of videos on my channel about it that may be helpful for you getting started. I try to answer comments and questions too if you ever get stuck. I'm double impressed with the new life you breathed into that bandsaw. Cleaning them is a real task.
Been watching you for years now man and one thing I've gotta say... HUGE congrats on the weight loss man!
I know many others haven't mentioned it but the fact that you stuck with it is such an accomplishment in it's own.
As for the videos, like others have said, do you man. We are here for the ride along, it's the quality that we are here for, not quantity.
Good to see you back in the saddle. That’s a nice mill. Aluminum loves surface footage. Especially with good carbide tools. I don’t know what that spindle goes up to but I would bet you could run that at max rpm with just about every tool you’re using except that face mill.
Most tools want over 1000sfm in typical wrought Al which on anything under 1/2 inch is likely to be over your max spindle speed.
What does that thing max out at for linear speeds?
Yeah I'm running carbide on everything, It came with all the end mills and tooling you see- luckily most of it is kennemetal or American-made carbide tooling. It's a 7500 RPM spindle, and in learning I'm erroring on the slow side which I think is problematic. I need to trust my tooling more, and my accidental rapid plunge into the corner shows that I can push all of those tools a lot harder and faster, probably to the benefit of tool life. She will do 400ipm.
@@WesleyKagan erring on the slow side is the better of the two tbh, but you would be amazed at what carbide can handle. Especially with the flood coolant. Depending on coating chip welding can be a pain but the coolant goes a long way to controlling that
I run my haas at 8-12k and with some variance to optimize finish on everything except my face mill I run at 6k.
My main roughing tool is a 12mm carbide no name I get from McMaster and I run that thing at 8k with an .06 radial, .75 axial at 220ipm (.007ipt) it munches through aluminum and it could go faster
Harvey tool has a great calculator to get you in the ballpark for speeds and feeds
Fusion also loves to default to G1 rapids with a hidden parameter that clips your max speeds. It looks like yours may be doing that unless the clips you showed were on rapid override.
Faster rapids are one of those things that seems arbitrary but will make a huge difference.
There is an option in a bunch of tool paths in the linking tab to set a no engagement feed rate and If you have a machine template setup I think you can change it there, and there may also be an option in your post. Just be careful if you switch it back to G0 rapids, a lot of older machines will dogleg on multi axis rapid moves (that aren’t a perfect 45* angle) and you have to be careful because it wont move where you think it will, or where fusion shows it moving. Only an issue if you like to run your clearance heights on the dangerous side or you have complicated part holding or fixturing that extends above the clearance plane
@@WesleyKagan also can’t wait for more m120 content. Mine is chilling on a pallet waiting for the motivation to come back 😂
Dude! It's that dude that does those things!
Joking... good to see you uploading again, my dude!
I do some things! Thanks! Good to be back!
I like people who admit they don't know something, but try and experiment. Thanks for the video, I think these machines are really lucky to be in your hands!
One of my favourite things is giving new life to old machines; glad this worked out and loved to see the progress of it.
My wife and I had a baby since you last posted
Congratulations!
Curious if you're a community fan and if that 80's end scene was a reference to the "Hard Drive and Wing Man" bit. I love your videos, if I had the money and the space I'd be doing pretty much everything you are :)
This comment is streets ahead.
Another wonderful video - love your content as always and can't wait for the next one!
Good to see you back! I've been loving the content you put out
Looking slim Wesley
Yup.
how much did it cost?
Looking forward to more! Congrats on the new tools
i have so much to say about how alike we think and how i get all the little references you throw in, all while being extremely interested in your projects and the subjects they involve, all while wrapped up in flawless presentation
We appreciate quality over frequency. Good work.
Great to see this upload! Looking forward to the next exciting episode.
Hi Wesley, great to see you again, fantastic videos, don't worry about the schedule
Thanks for sharing. Love your optimistic comments. Keep it up!
PS. Maybe add a spring to the clamping mechanism to help retract the holder when turning the wheel to release?
I'm jealous. These are the things that I wish I had for myself!
Congrats on the acquisition, I hope you enjoy many more years out of this machine.
One of the best engineering channels on CZcams
you have the knowledge and the workmanship that most people your age lack. good on you!
I loved " .. it is different flavor of electrons..." explanation. Marvelous.
Glad you're back!
I MISSED YOU!!! Thanks for uploading again. Love your content quality and how informative it is and your sense of humor. I'll be waiting very patiently for future videos.
Thanks for the kind words!
We still have 3 15xts in our shop. Running next to modern millturns. They are simple and sturdy machines that can be maintained to this day pretty easily. Good choice for a used intro milling machine
Love all your vids and will patiently wait for the next one
I was a machinist for 23 years programming, setting up and running 3 and 5 axis mills. I love this stuff glad to see people want to learn it still.
damn what a "comeback"! glad to see you posting again especially with the cnc, as someone trying to start my own dedicated machine shop out in texas! also, awesome sponsor, for sure will try out your service!
I did the exact same thing 6 months ago. I knew nothing about machining in general actually.
Taught myself how to use it even though there's no documentation online except I found an old manual for the acramatic 2100 controller and now im making parts!
love these videos , thanks so much, wish it could be more frequent but hey, it is what it is. Superb work restoring the machines
I'm glad to see you're back 😊
Learning and laughing at the same time. Thank you.
Great job. That band saw.looks great after that paint job😊
Fantastic work. I love your videos and projects. Keep up the good work. We don't mind how long between videos, we'll still watch.
So Great to see a new videos and so many updates
I just discovered you 2 days ago Wesley. Very good videos well worth watching. Thank you from the UK
Oh, there you are! Glad to see a new video.
Westley, Westley, Westley… I love your whole “old and probably fixable is more fun than new and working”-dynamic
Love the shop! Enjoying all of this! I hope you’re doing well Wesley!
Great to see ya back at it Wes!
Very cool to see the progression. I run a machine shop with Fadal's and they are very handy to work on compared to most CNC's. Even 25 years old with proper maintenance they will last another 25 easily. Good thing you're handy with electrical and what not. I'm not so into the mechanical side just machining. So I'm at the mercy of my technician. But your video inspired me to be more engaged with the things I use in my shop. To not be afraid to take something apart and not be worried about how it goes back together. Having a video setup would probably help alleviate some of my worries. But, I've done it in the past where I take something apart and cannot figure out how it goes back together then just ends up in the trash. Keep up the good work!
I loved this video… and the color you chose for the band saw
I just love your videos! Just don`t stop and keep them comming! Love from Norway!
Thanks! I appreciate it!
Good to see your back! keep doing what you do best, and we'll keep watching;)
Thanks! Will do!
New to the channel but everything you've uploaded is right up my alley, got yourself a new subscriber. Loved watching you get those machines up and running
Cool upgrades.
Looking forward to the next vid.
Really glad to see that you're still at these hobbies
Duuuuude! 9 months, i was seriously becoming worried about your well being! Glad to see you back on my feed ❤!
I have four Fadals. They are really quirky machines -- but are so incredibly reliable. Even being a 25 year old mill, you will be so glad you got a box way over linear bearing.
Glad you're back and stoked to see the video on the racecar!
Thanks! Looking forward to it myself too!
10/10. Thank you for posting.
Great work. Good to see you back
I opted for the VFD and it's nice because you can set a torque limit to cut power if the band jams
I honestly don't care how often you produce content. I love every moment and rewatch episodes all the time. I wish I had your knowledge and skillset or lived close enough that I could come give you a hand and learn on the way.
Nice job restoring the bandsaw!
Amazing work, channel and content, love it
Yo Kagan welcome back brother. Don’t stop making videos I love your content
Glad I found your channel. This is great content
First one of your videos I have seen, really enjoyed this. Looking forward to seeing what else you do.
The original control console is amazing.
Worth the wait!
Absolutely beautiful set of machines !
Thank you!
Love watching you fix up old broken machines. So satisfying. Wish my attempts to do the same were as successful
Sometimes mine aren’t as successful, but it’s something I do really enjoy. Thanks!
Wesley, great to see you again! Looks like you're doing well and keeping busy! The CNC and saw look like they came out great! Looking forward to more videos when you get a chance!
Thank you! Yeah, always have something going haha
Just found your channel recently, you’re very entertaining and the projects are massive and satisfying. Thanks for sharing! Looking forward to more 🤙
Thanks!
Casual legend over here god damn. You make it look easy mate.
whoa i was thinking you've stopped documenting your projects. good to see you back!
It lives, ooo -a spark!
Superb lathe XD
You look great, dude. Always love the vids no matter how far apart
Glad you like them!
Hey man! Stoked you got a mill! When fighting chatter its important to try to visualize your chip formation during cutting. Harder materials like much slower SFM. Aluminum likes much Higher SFM. If you are getting chatter its essentially because your tool is skipping across your work piece. There are a number of things to try. My personal order is first lower RPM. If that doesn't work, increase the feed. Next is to increase your step over and incremental depth. Solid carbide is meant to feed the crap out of. The point is that all of these solutions mean higher material removal rates and better chip formation. When you aren't cutting fresh material, you're just work hardening the surface of your material. That work hardened surface beats the crap out of your tools.
Again Congrats!!! Have fun cutting!