First project on converted Xenetech machine

[Gerald Wubs]

Well, I"ve finished cutting my first project on the Xenetech 13x13 that has been converted to G-code. It's done in Styrofoam SM using MeshCam (very nice code generator!). School project for my daughter Megan, who is studying Egypt with her grade 7 class. The machine never missed a beat through some 600,000 lines of code in 5 layers

[Mick A Martin]

Gerald,

Very nice project how long did it take to machine?

Mick

[Gerald Wubs]

About 20 hours run time for 5 layers. I kept the feed rates down to stop the cutter from ripping the material.

[Mike Heidrick]

You are very talented. Looks great!

[Gerald Wubs]

Thanks for the kind words. I'll post pictures of it painted up.

[Mick A Martin]

Gerald,

It looks like the project has a flat back, what was your total Z height?

[Keith Outten]

Gerald,

Great job on the project!
What type of glue did you use to adhere the foam pieces together?
.

[Gerald Wubs]

Mick, my total Z height of the model is 4.625". This model is made in 5 layers using MeshCam to do the layers. It's a snap to use. My machine stock had only 2" of Z, but I've redone the drive with a toothed belt, and eliminated the Z axis proximity switch for floating Z, so I managed to get another 5/8" of travel for 2.625" total.

Keith, I used white glue to bond layers, and coated the whole thing with about 15 coats of Delta Ceramcoat (craft store - Micheals) to stop foam melt. I've fogged on about 4 coats of conventional primer, and so far so good. Sanding is next, followed by hopefully a couple good full coats of Gold paint overall and then detail colour painting.

[Keith Outten]

Thanks Gerald,

I assume that by white glue you mean something like Elmers Craft Glue.
I will visit Michael's and purchase some Ceramcoat and give it a try.
.

[Gerald Wubs]

Hi Keith,
Yes, Elmers White glue is what I Used

[Gerald Wubs]

Got it painted! Krylon Metalic Brilliant Gold paint is INCREDIBLE. If you need something to be shiny,this is the stuff.DSC_5919.JPG

[Mike Heidrick]

That is amazing work. Not only the cnc convert, then the foam in 5 layers, and now the finish of it. I am really impressed. This is worth a permanent "How To" in my opinion. Thank you so much for sharing.

What bit did you cut the foam with? What is your spindle or router?

BTW - I have a Megan as well. She just turned 4ysld. She was out in the shop with me for a few hours tonight. turned some 2" PVC and fittings into a horn. I will post a pic up in my Vac thread. We had several marching band marches around the shop tonight.

[Mick A Martin]

VERY nice job Gerald, I bet your daughter loves it.

Mick

[Keith Outten]

Yep, its a real beauty Gerald.

Your project would make a very nice article. We would love to publish it for you if you have the time to write it up.
.

[Gerald Wubs]

Once again, thanks for the compliments everyone. I had promised earlier to post some detail of the Xenetech 13X13 conversion to G-code, so I'll do that. As for a how to article on the King Tut project, well I think I might just be able to do that too.
The spindle is the stock Xenetech one, but modded to take a Porter Cable router collet. This will probably make engraver folks cringe, but it runs within .0005" TIR, so I dont feel bad about that. The cutter I used is a brand new Freud Ø1/4" ballnose. The flutes on that are only 1/2" long, but it worked well. I also picked up an eighth inch ballnose, but it stepped up to 1/4 inch before the 1 inch depth depth I needed, so that was a no go. Think of the increased detail that might have been possible on the face...
Keith, my wife very properly pointed out that I need to give more detail on the Delta Ceramcoat product that I used as a foam sealer. The full description is "Delta Ceramcoat All-Purpose Sealer", and is a "Prep" stage item.

Gerald