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NeilBlanchard · 09-22-2011, 08:58 AM

It makes total sense! I am looking to improve the 3 or 4 critical things:

I ordered 4 of the rails with nylon wheels that Jethro linked to -- this is the key point both for the bit overheating, and for the cutting accuracy. The upper part of the shank is where the cotton candy is forming when the second cut has wandered from the first cut.

My brother Nathan told me about a company nearby that has some longer bits that should let me (safely) cut through the sheet, and hopefully they have flutes that are 2"+ so they can cut and clear the foam if it does wander (a bit). My ideal bit would be 2.5-2.75" (63-70mm) long, ~4-5mm (5/32"-3/16") in diameter, have a cutting edge that is 2 1/8" (~55mm) long with an up spiral flute. I am waiting to hear back from them.

My current bit is ~2 1/4" long and the up spiral flutes are about 1 3/8" long and are 4mm in diameter. (Sorry for the mixed units!) I am only cutting down about 1 3/4" which makes removing the cut pieces from the sheet quite messy and problematic.

The third thing that I'll probably need to do is rig up an air nozzle that blows directly at the top of the bit. I have also cleaned out the filter on the central vacuum system -- it is very powerful, but obviously it works better when it is not got a ton of fine gunk in the filter.

The fourth thing that I can do is shorten the lengths of the cuts, and set it to cut through the foam, and insert the tabs. If the bit lifts out of the foam frequently, and if the cut lengths are kept short, and if the dust can drop out of the bottom of the groove, then I can get quality smooth edges (and even then increase the cutting speed), I will be on my way!

It will be GREAT to get started on building the chassis of CarBEN EV5! I'll need to learn about fiberglassing, and I need to design and build hinges for the doors, the hood and the front wheel skirts. I'll need to buy a windshield (and the wipers) of a Smart ForTwo and fit that into the chassis. Then I need to find a front wheel drive front suspension with manual steering. And the rear suspension will probably have to be custom fabrication -- probably trailing arms with a lateral link and coil springs.

Then a driver's seat (in the center), steering wheel, dashboard, etc. -- and then a dual motor direct drive drivetrain with a 50kWh+ battery pack in the floor!

That's all... :-)

09-22-2011, 08:58 AM	#307 (permalink)
NeilBlanchard Master EcoModder Join Date: May 2008 Location: Maynard, MA Eaarth Posts: 7,908 Mica Blue - '05 Scion xA RS 2.0 Team Toyota 90 day: 42.48 mpg (US) Forest - '15 Nissan Leaf S Team Nissan 90 day: 156.46 mpg (US) Number 7 - '15 VW e-Golf SEL TEAM VW AUDI Group 90 day: 155.81 mpg (US) Thanks: 3,475 Thanked 2,952 Times in 1,845 Posts	It makes total sense! I am looking to improve the 3 or 4 critical things: I ordered 4 of the rails with nylon wheels that Jethro linked to -- this is the key point both for the bit overheating, and for the cutting accuracy. The upper part of the shank is where the cotton candy is forming when the second cut has wandered from the first cut. My brother Nathan told me about a company nearby that has some longer bits that should let me (safely) cut through the sheet, and hopefully they have flutes that are 2"+ so they can cut and clear the foam if it does wander (a bit). My ideal bit would be 2.5-2.75" (63-70mm) long, ~4-5mm (5/32"-3/16") in diameter, have a cutting edge that is 2 1/8" (~55mm) long with an up spiral flute. I am waiting to hear back from them. My current bit is ~2 1/4" long and the up spiral flutes are about 1 3/8" long and are 4mm in diameter. (Sorry for the mixed units!) I am only cutting down about 1 3/4" which makes removing the cut pieces from the sheet quite messy and problematic. The third thing that I'll probably need to do is rig up an air nozzle that blows directly at the top of the bit. I have also cleaned out the filter on the central vacuum system -- it is very powerful, but obviously it works better when it is not got a ton of fine gunk in the filter. The fourth thing that I can do is shorten the lengths of the cuts, and set it to cut through the foam, and insert the tabs. If the bit lifts out of the foam frequently, and if the cut lengths are kept short, and if the dust can drop out of the bottom of the groove, then I can get quality smooth edges (and even then increase the cutting speed), I will be on my way! It will be GREAT to get started on building the chassis of CarBEN EV5! I'll need to learn about fiberglassing, and I need to design and build hinges for the doors, the hood and the front wheel skirts. I'll need to buy a windshield (and the wipers) of a Smart ForTwo and fit that into the chassis. Then I need to find a front wheel drive front suspension with manual steering. And the rear suspension will probably have to be custom fabrication -- probably trailing arms with a lateral link and coil springs. Then a driver's seat (in the center), steering wheel, dashboard, etc. -- and then a dual motor direct drive drivetrain with a 50kWh+ battery pack in the floor! That's all... :-) __________________ Sincerely, Neil http://neilblanchard.blogspot.com/ Last edited by NeilBlanchard; 09-22-2011 at 09:08 AM..