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Gyro Mount Machining Plan (Revised)

by Joseph Rinek — last modified Jan 10, 2010 06:20 PM

Start with Aluminum or Nylon Block of dimensions 2.71 x 2.64 x 3

 

1st Cut (front material removal):

Tool: 1" end mill

Total Depth: 1.14"

RPM: 1000

Passes: 3

Pass Depths: .5", .5" , .14"

1st cut

 

1st cut drafting

 

2nd Cut (right side shape):

Tool: 1/2" end mill

Total Depth: .5"

RPM: 2000

Passes: 2

Pass Depths: .25", .25"

2nd cut
2nd cut

 

3rd Cut (left side shape):

Same as 2nd cut, but opposite side

2nd cut

 

4th Cut (head tube recess):

Tool: .5" end mill

Total Depth: 1.464"

RPM: 2000

Passes: 3

Pass Depths: .5", .5", .464"

head recess
head tube recess

 

5th Cut (14* top piece angle cut):

Tool: .5" end mill

Total Depth: .3"

RPM: 2000

Passes: 1

Pass Depths: .3"

Clamp to a 14* mounting block

angle mount
4th cut drafting

 

6th Cut (top tube recess):

Tool: .5" end mill

Total Depth: 1.1435"

RPM: 2000

Passes: 3

Pass Depths: .5", .5", .1435"

Clamp to 14* angle block

top tube recess
top tube recess drafting

 

7th Cut (top piece flange trim):

Tool: 1/4" drill bit

Total Depth: 1/16"

RPM: 2500

Passes: 1

Pass Depths: 1/16"

Clamp to 14* angle block

Take 1/16" off the top piece flanges

 

8th Cut (head flange trim):

Tool: 1/4" drill bit

Total Depth: 1/16"

RPM: 2500

Passes: 1

Pass Depths: 1/16"

Take 1/16" off the head tube flanges

 

9th Cut (head flange holes):

Tool: 6mm drill bit

Total Depth: Through hole

RPM: 2500

Passes: 1

Pass Depths: Through hole

head flange holes
 
3rd cut drafting

 

 

8th Cut (top flange holes):

Tool: 6mm drill bit

Total Depth: Through hole

RPM: 2500

Passes: 1

Pass Depths: Through hole

Clamp to 14* angle block

top flange holes

 

 

 

 

 

 

 

top flange holes

 

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couple things

Avatar Posted by Jason Moore at Jan 10, 2010 10:54 PM
Joe, On the first cut, can you have all straight corners? Won't some of them need to have a radius because of the endmill? And think about drilling the hoels before the 4th cut, that way you can bolt the fitment to the triangular block securely before cutting the radii to fit the bike tubes.

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