Build Thread - Chevalier 2040 CNC Bed Mill

[Coolidge62]

The hella long table gibs lubricated and ready for install. I ended up replacing the hardware. The black oxide screws were rusty, one of the long ones was bent. The original nickel plated nuts were sort of 'okay' but as I was already at the hardware store I raided the chrome fastener automotive bins for some new chrome plated nuts.

[Coolidge62]

The pucker factor was 9.8 at this stage. The table was upside down on the workbench, I had to lift it then flip it over 180 degrees right side up in midair with the two dualling engine hoists while avoiding damaging the ball screw. Here I have it leveled and ready to hopefully slide right into the dovetail ways on the Y saddle.

[Coolidge62]

Houston, we have a problem. lol When I removed the table I heard a 'tink' and looked up inside and found that INFAMOUS brass elbow had sheared off of the ball screw nut. Sure enough when I went to re-install the table, it doesn't fit through that small rectangular opening on the Y saddle. It's a good .100 too wide if not more. I thought maybe I could spin the table a bit with the gibs out, NOPE!

So obviously someone at the factory made an oops, not accounting for that brass elbow. I had to loosen the ball screw nut, pull it back so that I could remove the brass elbow, because the infernal thing whacks up against the ball screw nut mount with the screw installed...of course it does.

THEN push the table on and out the other side of the saddle. Fish my arm elbow deep up through that tiny opening, blind, and install the brass elbow (not bad) then the brass compression fitting/tube into the elbow (maddening). My man arm and paw are clearly too large for this operation, but it's done and back together!

Then I spent a few hours prepping the table top for paint. First job was using a carbide bit to knock off all the casting flashing from the coolant channel. There was so much of it and so sharp it would literally shred a shop towel if you tried to wipe it out. The Dremel and that bit did a pretty good job!

Now waiting for paint to dry again with half the machine masked off I'm going to work on installing the new electrical cabinets.

[Coolidge62]

Table top edge and coolant channel now painted black. I had to do a lot of smoothing in the coolant channel with a carbide bit, it was quite jagged with casting flash and shredded shop towels.

[Coolidge62]

Hmmm how to mount the behemoth Powerohm dual braking resistor for the spindle motor...

1/2 x 6 x 12 aluminum plate and some aluminum spacers, check!

Space heater get up there out of the way and stay cool.