Kondia FV-1 Head disassembly

[PixMan]

Yeah, it might be to access a set screw (grub screw in your dialect?) on that black ring. If that's the case, it's fine with a smaller radius and gives even more clearance.

[Mayhem]

Just checked and it is for a ø9.82mm set screw that retains a detent ball for the fwd/n/rev selector.

[PixMan]

So we're OK going with my proposal then?

[Mayhem]

I believe so

[PixMan]

That took all of 15 minutes, half of which was finding an end mill of about .140" (9/64") diameter. The 5/32" one I found had corners that were either radiused from the start or just worn, but it worked well enough to blend seamlessly with the 1/8" radii of the 1/4" ball mill I used.

All that remains is to get the 60mm long Ø16mm bore done and mill the 6mm wide x 28mm long slot to it. I'm going to try and find an extra long end mill under 6mm, but if I can't get one would it hurt anything to mill it with the part standing upside down in the vise and leave a radius where the slot stops?

[EdK]

That sure looks complicated to mill. Way beyond my capabilities.

Ed

[PixMan]

Well, it's testing my skills too Ed.

Remember, the more operations there are on a part, the more opportunities there are to screw it up. And I sometimes do.

The project has been a good (if a bit frustrating) exercise for me to get more familiar with what my Prototrak control can and cannot do. It's getting easier, but the control is still unpredictable as to when it will execute sequential blocks of motion commands without stopping.

Also, working with a European "third angle projection" print intended for a casting has been a valuable learning experience.

I anticipate getting the 16mm reamer on Monday or Tuesday, and hope to finish the last two operations this week. If I get it done I can ship out this part plus the knee elevation screw and nut by week's end.

If I get it shipped, Darren should have the package by the middle of September.

[EdK]

(07-05-2014, 09:20 AM)PixMan Wrote: ...

If I get it shipped, Darren should have the package by the middle of September.

I think that's spring time for him and probably cooler for him than it is now. Good time to work on the mill.

Ed

[DaveH]

That is a really smart bit of machining there Ken

DaveH

[PixMan]

(07-05-2014, 12:03 PM)DaveH Wrote: That is a really smart bit of machining there Ken

DaveH

Thanks Dave! It doesn't look quite like the original casting, but it's about as close as I can get without 3-D profiling capabilities. There's a couple of "visual" details that I'm not happy with, but it's meeting all the given dimensions so far. I'll dress it up a little with my Scotchbrite wheel once I've finished all the machining operations.

I got the 16mm reamer in the mail today, and found a 6mm 4-flute TiN-coated solid carbide end mill in the shop. I'll just have to relieve the 1/4" shank on the end mill back so I can get the 19mm depth I need. In order to do the reaming I'm going to have to make a 3/4" O.D. bushing to hold a 3/8" solid carbide insert boring bar in my boring head and then bore the 9/16" drilled hole I did this afternoon. I think I'll leave about .012" to .015" for the reamer to size the hole.

The part could be done tomorrow, but no promises.