A small but important job for a friend - Router Forums
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post #1 of 18 (permalink) Old 09-17-2013, 10:02 AM Thread Starter
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Default A small but important job for a friend

I have a friend who is a semi-retired optical dispenser and asked if I could come around to see if I could make a part for a machine that traces the lens shape and feeds the info. to the router. The broken part turned out to be a large knob that performs a critical adjustment, it had disintegrated and a replacement was no longer available. My friend thought that I could make one out of wood.
I decided that Acrylic would be a better choice, the piece of half inch Acrylic that I decided on turned out to be very difficult to rout even at the slowest speed and with a 1/4" bit, it was melting and forming hard blobs. I persevered and these shots show how I went about it.
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Harry



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Last edited by harrysin; 09-17-2013 at 10:06 AM.
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post #2 of 18 (permalink) Old 09-17-2013, 10:19 AM
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Plastic is SO hard to work with Harry! Awesome job!!! I had to cut acrylic with my scroll saw, and had the same problem with melting. You're a fine example of "if one way doesn't work, you go around and pull a surprise attack to win the project war" lol

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post #3 of 18 (permalink) Old 09-17-2013, 11:08 AM
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Clever solution to cutting the scallops, Harry. I'm jotting that one down in the memory banks for future reference. Thanks for the easy-to-understand story-telling photos.

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post #4 of 18 (permalink) Old 09-17-2013, 11:15 AM
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!!!....brilliant idea for the accurate depth control, Harry! Who'd a thunk of using a drill bit shank as a gauge block. As Oliver said, that's going down for future reference (no pun intended).
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post #5 of 18 (permalink) Old 09-17-2013, 11:50 AM
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Good job, Harry. I think you saved the day for that fellow.
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post #6 of 18 (permalink) Old 09-17-2013, 11:50 AM
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Harry, your friend used good judgement when he asked you for help as he availed himsleve to talent that is unequaled in most circles of endeavor. Applaud you as well as your friends judgement in regard to be wise enough to know who to ask.

I am not just blowing smoke at you Harry, I do admire your talent and ablility to communicate with the members of our forum.

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post #7 of 18 (permalink) Old 09-17-2013, 02:22 PM
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Another great job, Harry. Thanks for the tutorial.
I agree about the melting.
Barb, Leave the protective paper on both sides of the acrylic. You won't have as much melting. Doubt that would help much with anything thicker than 1/8", though.
I needed to make 48 disks from 1/8 Lexan. It only comes with the plastic protective covering. It was quite a job to clean the edges of the melted stuff. Oil helped with cooling. Quite messy.

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post #8 of 18 (permalink) Old 09-17-2013, 03:01 PM
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how many times did you have to clean out the file? Plexiglass can load up a file pretty quick in my experience. Nice job.

I still have to find the time to build your lighted sub base... my eyes are getting a little older, I hate to say, and every bit helps!

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post #9 of 18 (permalink) Old 09-17-2013, 07:17 PM
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You must have a large 'memory bank', Harry.

Every time you post, the forum learns something....

Great job, BTW.

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post #10 of 18 (permalink) Old 09-17-2013, 09:04 PM Thread Starter
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I really do appreciate all your kind remarks. I have never purchased acrylic material, as with wood, I have friends who know that I appreciate FREE materials, only a week or two ago I was given the Acrylic shown in the photo that I just took. Most of the time I have no idea what type the Acrylics are, once in a while it's written on and the easiest that I've ever routed was Poly-carbonate.
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Nothing but heaven itself is better than a friend who is really a friend. - Plautus






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