CNC Epoxy Inlay Backgammon and Cribbage Board

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I’m using my CNC router to make a travel-sized backgammon and cribbage board, inlaid with epoxy and colored mica powder.

Part 1 – Milling Stock, Cutting Pockets

In this first installment I introduce the project, mill the wood to size, and set up the CNC router to cut the inlay pockets on the backgammon board.

Part 2 – Backgammon Inlay

In the second installment I mix the mica and epoxy, and pour the inlays.

Part 3 – Special Details

In the third installment I add gold edges to the points on the backgammon board, and make the inlay and holes on the cribbage board side.

Part 4 – Finishing It Up

In the fourth and final installment I dye the wooden playing pieces and build the finished boxes with splined miter joints.

Resources

Here are links to some of the tools, materials and software that I’m using in this project:

AutoDesk Fusion 360 for personal use
Blender software
Next Wave CNC Shark Router
Carbide 2-flute Down-cut end-mills
Mica Powder for Epoxy Resin
West System Epoxy
Wooden checker pieces
Wooden cribbage pegs
Keda Aniline Dye 5 Color Kit

CNC Feeds & Speeds

UsageBitRPMDepth of
cut
Plunge
mm/min
Cut
mm/min
Comments
Roughing0.1250″ (3.18mm)
2-flute downcut
250003/32″ (2.38mm)500800
Finish0.0313″ (0.80mm)
2-flute downcut
250003/32″ (2.38mm)200250
Drill0.1250″ (3.18mm)
4-flute upcut
250000.25″ (6.35mm)
200n/aPeg holes
Engrave0.1250″ (3.18mm)
30-degree point
25000Variable400400V-carved text

Wood Dye Info

I dyed the playing pieces using a Keda Aniline Dye 5 Color Kit, and I mixed it following the manufacturer’s instructions but with a higher ratio of dye to water to get more concentrated colors. Here are the amounts of dye I mixed with 3 ounces of warm water:

Red: 1/8 teaspoon
Blue: 1/4 teaspoon
Green: 1/8 teaspoon yellow + 1/4 teaspoon blue
Purple: 1/8 teaspoon red + 1/4 teaspoon blue

Next time I use the blue dye, I’ll mix it with hot (not just warm) water in hopes of getting it to dissolve better.

3D Printed Ornaments

Watch how I use my 3D printer to make unique ornaments to give away to family and friends.

If you have a 3D printer and want to print these ornaments yourself, here is a 10MB zip archive containing STL files for the four 3D models that I created:

Quick Mount Camera Boom

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I made a quick-release mount for this 7-foot camera boom to shoot videos from various locations in my workshop.

Here are links to the parts that I used:

Impact 7 ft HD Wall-Mounted Boom Arm
DMKFoto Heavy Duty Ball Head with Quick Release Plate
Konsait Black Camera 323 Quick Release Plate
IRWIN Step Drill Bit, 3/16-Inch to 7/8-Inch

The ball head listed above is inexpensive but its quick-release is not compatible with Manfrotto quick-release plates, which I use on all my gear. So I changed out the plate for the quick-release listed above. You can also get Manfrotto ball heads that come with their quick-release plate, and they’re a bit more expensive but good quality.

My main cameras are a Panasonic GH5 and a Panasonic G95, and prefer to use the G95 on the camera boom because it’s lighter weight. I also have an older Canon EOS Rebel SL1 that I used to shoot many of my previous videos and that’s what I’m showing on the camera boom in this video.

Portable Wood Fired Pizza Oven

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This video shows how I built a portable wood-fired pizza oven that’s inexpensive, easy to build, weighs only 7.5 pounds, and can be carried easily in a backpack. And it makes fantastic pizza too!

Also see our Cooking with Fire event where we used this oven along with some other great fire cooking techniques.

Get the Shirt!

Click here to see our Pizza + Fire = Awesome T-Shirt on zazzle.com:

Pizza + Fire = Awesome T-Shirt

Materials List

Here are the materials I used to build this oven. I recommend getting these materials locally but in case you can’t, I’ve included links to amazon.com.

Tools

These are the tools I used for this project, again with links in case you have trouble finding any of these items:

CNC Guitar Inlay

Here’s how I designed a shell inlay for a guitar headstock using Fusion 360, and cut the inlay using my CNC router.

Part 1 – Design in Fusion 360

Part 2 – Cutting Shell Material

Resources

Here are links to some of the tools, materials and software that I’m using in this project:

AutoDesk Fusion 360 for personal use
Next Wave CNC Shark Router
Carbide 2-flute Down-cut end-mills
1/32″ Carbide shell cutter
Phenolic backer board

CNC Feeds & Speeds

UsageBitRPMDepth of
cut
Plunge
mm/min
Cut
mm/min
Comments
Wood pocket0.0313″ (0.80mm)
2-flute downcut
250000.5mm roughing
0.2mm finish
200250
Shell0.0313″ (0.80mm)
shell cutter
250000.3mm125250

Welding Cart

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I built this welding cart to hold my new Everlast PowerPro 205S TIG Welder and Plasma Cutter as well as my Lincoln MIG Welder. The cart features a large work surface and five hitch-style attachment points for mounting accessories such as a bench vise and camera supports.

Resources

I used SketchUp software to design the cart, and here is the model file: WeldingCart.skp. You are welcome to download this model and customize it any way you like.

Here’s a link to the Menard’s Masterforce 30-inch Five-Drawer Mobile Tool Cabinet around which this cart is built.

I used a 4 in. Swivel Vise with Anvil from Harbor Freight. It’s an inexpensive vise but the quality is good enough for my purposes.

Also from Harbor Freight I bought the 8 in. Deep Throat U-Clamp and 12 in. Deep Throat U-Clamp for under $10 each. The 12-inch clamp is deep enough to reach almost anywhere on the 25-inch wide work surface of my cart. Their quality seems pretty good for the price.

4th Axis Harmonic Drive

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After finishing my Modular CNC Controller I built this 4th axis attachment for my CNC router and my milling machine. This will let me machine parts such as gears, and carve 3D patterns wrapped around cylindrical shapes. In the Part 1 video I build the main drivetrain components, using a harmonic drive gearbox to get precise angular positioning and high torque with low backlash.

In the Part 2 video I weld and machine the steel enclosure, install the harmonic drive system, and try it out.

In this video I apply Powder Coating to the housing.

Documentation

The Harmonic Drive web site has detailed information about the style of gearbox that I used. The Catalog link on that page provides detailed documentation about this family of ultra-low-backlash gearboxes.

I bought the 3-jaw front-mounting self centering lathe chuck from Shars. Any similar chuck should work, provided that it can be mounted from the front.

I bought my stepper motor on Ebay after quite a bit of searching to find one with the specs I wanted, including the 8mm output shaft to fit the coupling on my particular gearbox. Here is a link to a similar Nema 23 stepper motor on Amazon.com, but with the more common 1/4″ output shaft.

Aquaponics

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Aquaponics is a combination of aquaculture (raising fish) and hydroponics (growing plants without soil). The wastes from the fish are broken down by bacteria living in the growing medium, and converted into a form that can be used by the plants.

Integrated Vertical Tube System
Here’s a drawing and a photo of the integrated vertical tube aquaponics system we built. The photo shows the tubes in the planting/harvesting position; normally they are rotated 180 degrees so that the openings face the window.

I made the drawing using Google SketchUp, a great free 3-D drawing program. If you have SketchUp and want my drawing file you can download it by clicking here.

To make the grow tubes, I cut slots across with a hack saw and then heated the plastic with a heat gun to soften it. Once it was soft I pushed in a tapered wooden plug to hold it open until the plastic hardened again. I did this outside because the PVC gives off some fumes when you heat it. The second photo below shows a close up of one of the openings after the tube was filled with pea gravel.

The PVC caps on the bottom of the tubes have slots cut around the edges with a table saw, so that any water that might drip out around the plants can just run down the outside of the tube and through the slots. Otherwise the cap would seal against the funnel and the water could not drain. Normally the water flows down through the tube and out the holes I drilled in the bottom of the cap.

The photo below shows the top of the system, with the flow control valves that regulate the flow of water to each tube. These were necessary in order to balance the flow because without them, most of the water runs into the tube closest to the pump. Note that the tubing is black in order to prevent algae from growing inside it, but after a while it will still develop a film inside from beneficial bacteria that break down the fish wastes. We found that it was necessary to clear the tubes out now and then, by closing all but one valve and turning the pump off and on. The sudden surge of water when the pump starts is enough to clean the accumulated biofilm that adheres to the inside of the tubing.

April 3, 2007  We got fish today! They are about 3″ long and cost us $3 apiece. Their first meal was a small handful of earthworms, which they ate eagerly. I think the one in the bottom picture is burping.

Here’s my new experimental setup to permit multiple fish to each establish a breeding territory in one tank:

5-2-2007  Here’s our first harvest of lettuce, which totaled a whopping 9 grams (0.3 ounces)! The lettuce is a red variety so the color is normal for this type.

6-3-2007: We’ve had quite a few salads now and the plants are doing great. The spinach is spindly but the basil, upland cress and lettuce are thriving.

8-14-2007 We’ve got babies! We hadn’t looked closely for a while so we were surprised to see about 50 little tilapia in the tank today and they’re already over 1 cm long. The water isn’t normally this cloudy but we just cleaned the tank so it’s all stirred up.

The adults are doing well too, and they’ve grown quite a bit.

9-3-2007: The first group of babies have grown to about 1″ long, and we now have a second brood of little ones. The adults pretty much ignore them but the larger babies will “thin out” the smaller ones for us. It’s survival of the fittest in this tank!

Epilog: We shut down this project in the spring of 2008, in preparation for moving to Michigan. We ate the largest of the fish, which weighed in at about 10 ounces – not quite market size but enough for a taste anyway, and it was pretty tasty.In retrospect we wouldn’t undertake any serious fish-raising project without first developing a food source, as purchasing fish food getsrather pricey plus there’s no control over its contents. We’d also use a tank that’s easier to clean!

4th Axis Engraving a Micrometer Dial

This project is the first real test of the new Modular CNC Controller and 4th Axis Assembly that I built. I used themto engrave a micrometer dial to make an adjustable carriage stop for my metal lathe, which is based on a YouTube video by Tubalcain. Here’s how the finished part looks:

The first video shows how I modeled the part and created engraving toolpaths using AutoDesk Fusion 360:

The second video shows the machining of the dial using the toolpaths generated in Part 1:

I ran into some difficulties during the machining, one of which was that my cheap stepper motor drivers were not able to keep up with the pulse rate coming from the DDCSV1.1 control panel. Upgrading them to higher-end drivers solved the problem, and the specific ones I’m using are the KL-5056 from Automation Technology:

This driver supports a power supply up to 50V and can deliver up to 5.6A of current, which is more than I need for the steppers I’m using at the moment, but I also plan to use these drivers someday to run my milling machine where I’ll need bigger stepper motors. I have the drivers set at 2.7A for the smaller stepper motors that I’m using on the CNC Shark router and the 4th axis. I noticed that in addition to solving the problem I was having with lost steps on the Z axis, the improved drivers also gave noticably smoother motion and less noise.

Modular CNC Controller

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I built this modular CNC controller to run a variety of different machines in my shop. My first application is to replace the old controller on my CNC Shark router but I wanted the flexibility to reuse the same hardware on different machines, so I came up with a standard connector layout that will let me swap the controller and power supply for different needs. Initially I’m using the DDCSV1.1 Control Panel but I could someday replace it with a different standalone controller or an Ethernet SmoothStepper and Mach3 or Mach4 software.

The second video covers details of wiring and configuration of the CNC controller.

DDCSV1.1 Control Panel Documentation

Here is the DDCSV1.1 User Manual that contains a wealth of information about this panel, including details of wiring and operation.

Construction Details

Here are links to most of the parts that I bought on Amazon.com:

  1. DDCS 4 Axis Control System
  2. KL-5056 20-50VDC 5.6A Digital Bipolar Stepper Motor Driver – 32 bit DSP Based
  3. BUD Industries AC-405 Aluminum Chassis, 7″ Length x 7″ Width x 2″ Height, Natural Finish
  4. 2P5T 2 Poles 5 Position Rotary Switch
  5. Ferrule Crimp Tool Kit
  6. Remington Industries 18UL1007STRKIT UL1007 18 AWG Gauge Stranded Hook-Up Wire Kit
  7. Connectors Pro DB37 Female D-Sub Solder Type Connector, 10-PK
  8. D-Sub Hex Head Screw with Nut 4-40UNC
  9. 400W 36V Switch Power supply, DC power S-400-36 11A
  10. URBEST Inlet Module Plug 5A Fuse Switch Male Power Socket 10A 250V 3 Pin IEC320 C14
  11. US 3 Pins Power Socket Plug Black AC 125V 15A
  12. Blue Sea Systems Push Button Reset-Only CLB Circuit Breakers with Quick Connect Terminals
  13. uxcell DB25 25 Pin Female to Male Solder Type Adapter Connectors 5 Pair
  14. 12mm 5 Pin Aviation Connector Male Female

I laid out the openings in the aluminum case for the pendant and cut out the front panel using my Dewalt scroll saw. The end panel couldn’t be cut on the scroll saw so I used a nibbling tool to make the openings for the USB and DB37 connectors. I also added aluminum L channels on the back of the case in order to mount the control panel:

The wiring was pretty straightforward but there were a lot of connections, and because most of them used screw terminals I used crimp ferrules on the wire ends. This was the first time I had used crimp ferrules and they worked great, much more secure and neat looking than bare wire ends.

The signal wiring is all 22-AWG stranded wire, and here’s the pinout that I used on the DB37 connector:

I couldn’t find an off-the-shelf enclosure of the size that I wanted for the power supply module so I made my own from aluminum sheet using my ShopFox box and pan brake and plate shear. I ran the AC power from the switched inlet to a 10A circuit breaker, and then to the two power supplies. I also added an AC outlet to run the cooling pump for my 2.2KW water cooled spindle. On the 36V 11A supply for the stepper motors, I added a 22,000 microfarad capacitor to help absorb the current spikes from the stepper drivers.

The output current of the stepper drivers is configured using DIP switches and I have them set for 2.8A output current, which is the rating of the stepper motors in my CNC router. I could have used a larger power supply and drivers that would be sufficient to run the larger 6A stepper motors I plan to use on the milling machine, so that a single power unit could run either machine. But that would require changing the DIP switches when moving it between machines, which is inconvenient and error-prone so I chose to dedicate this power unit to running medium-size steppers and to build a separate one for the mill. I could still use this power unit on another machine such as my metal lathe, as long as I use stepper motors with similar current requirements.

I set the stepper drivers for 1/16 microstepping, and the CNC Shark HD router’s X-Y lead screws have multi-start threads with a lead of 0.5 inch or 12.7 mm per rotation. So with 200-step stepper motors, the pulses per millimeter are calculated as 200 * 16 / 12.7 = 251.969. This number must be entered into the settings page on the CNC controller. The Z-axis lead screw has a finer lead of 0.25 inch or 6.35 mm per rotation so its setting is 503.937 pulses/mm.

Software

I use AutoDesk Fusion 360 to model 3D parts and to generate CNC toolpaths using its CAM capability. AutoDesk makes this software available FREE to hobbyists and it’s very powerful. It has a steep learning curve but there are lots of tutorials available for it. I initially started using Fusion 360 with the original controller for my CNC Shark router, but unfortunately it lacked a post-processor to generate compatible G-code so I wrote my own post-processor for it and the resulting G-code works with the original CNC Shark controller as well as the DDCSV1.1 control panel that I’m using now. To use this post-processor with Fusion 360, follow these steps:

  1. Right-click on this link and save the target file to a directory of your choice, and rename the file with a .cps extension. The post processor is written JavaScript and it includes an open-source license that lets you use and copy it freely, but entirely at your own risk.
  2. In Fusion 360 select the CAM workspace, create a milling operation and generate a toolpath from it. You can find online help on CAM if you don’t know how to get that far.
  3. Once your toolpath is generated, select it and either right-click to select the Post Process menu, or select the Post Process button on the toolbar at the top. Again you can find online help on post-processing if you need it.
  4. In the Post Process dialog, under Configuration Folder enter the path to the folder where you saved the post-processor file in step 1. Then the DDCSV11 post-processor should appear in the drop-down list under Post Configuration. Pressing the Post button will generate G-code that should work on the DDCSV1.1 controller, as well as on the original CNC Shark controller.
  5. Transfer the resulting G-code file to the controller and run it. I strongly recommend “cutting air” at first, to test the G-code before performing actual machining with it. My usual technique is to raise the Z axis well above the part and then zero it out, so that I can test the code without actually cutting anything until I believe it’s correct.

Coolant Control
The latest revision of this post-processor supports the M8/M9 output, which will be activated while running any toolpath with any Coolant setting other than ‘Disabled’. This output can be used to control a coolant pump for liquid cooling, an air valve for air blast cooling, a vacuum for dust removal etc. It has limited current capacity so an external relay is required for controlling any high-current loads. Please refer to your DDCS controller manual for documentation of the M8/M9 output.

You may email me at Jay (at) BrainRight (dot) com with reports of any problems or requests for enhancements to this Fusion 360 post-processor, but I provide it at no charge with no guarantee of any kind and I may or may not respond to requests for changes.