swhillier wrote:Here's a couple of closer pictures of the exhaust deflector:
Here's an overview of what is in the DXF and the steps to cutting out the deflector. I cut mine from 12.25mm UHMW plastic using both a 3.175mm (1/8") end mill and a 6.35mm (1/4") end mill. I also flipped the deflector over to do the counter sinks for the screw holes. That's why there's an extra 80mmX80mm box around the deflector. It allowed me to use my G55 fixture which has known zero location and flip the 80mmX80mm piece to do the cuts on the back side.
I used 800mm/min feed and 300mm/min plunge with 2.5 mm cutting depth for the 3.175mm end mill and 3mm cutting depth for the 6.35mm end mill. I had the DWP611 on speed 1 for all cuts. I used climb cutting for the profile cuts and mixed cutting for the pockets.
I placed the stock in my G55 fixture so I could do a tool change between the 3.175mm and 6.35mm end mills.
1 - Put in the 3.175mm end mill, home the S03, enter G55, G0X0Y0, set Z0 with my probe sensor. Then drill out the two 4.2mm holes.
2 - G28 is my tool changing position. Change to the 6.35mm end mill, home the S03, enter G55, G0X0Y0, set Z0 with my probe sensor. Then cut a pocket for the circle labeled 2. I cut a 2.5mm deep pocket and when tightening the screws down there was a bit of a gap so the deflector wasn't level. I added a bit of tape to the lip of the deflector (where the 7 is) to level it. You could try 3mm or 3.5mm and it may work better.
3 - Profile cut circle 3 with the 6.35mm end mill. I used 2 holding tabs here.
4 - Drill out the two circle 4's for the LED holes with the 6.35mm end mill.
5 - Pocket cut out the exhaust areas labeled 5 with the 6.35mm end mill. I cut mine to a depth of 10mm.
6 - Profile cut the outside of the deflector. This is sized to be slightly smaller than the router diameter so it can be left on when installing or removing the router from the SO3 mount. I had 4 holding tabs on this profile cut.
7 - Now profile cut the square labeled 7. Again I had 4 holding tabs for this profile cut.
Now remove the stock, and cut the tabs and clean up the edges for square cut in 7. Leave the holding tabs in place for 6 and 3. I flipped the 80mmx80mm piece over top to bottom and placed it back in the G55 fixture. Then homed the S03, entered G55, G0X0Y0 and set Z0 with my probe sensor.
8 - Pocket cut the two 8.5mm circles labeled 8. I cut mine 10.25mm deep but the important thing here is that 2mm of material be left at the bottom of the pocket. With 2mm of UHMW its still strong enough to hold while shallow enough to re-use the stock screws for the router lock mechanism.
Now clean up the holding tabs and you have your exhaust deflector. To install it, hold the router with your left palm against the router bit lock. Use your right hand a torx screwdriver to take out the lock screws. Keep the router lock mechanism in place with you left hand while placing the deflector on the router and then re-tightening the lock screws. Again if the deflector isn't quite level when the screws are tightened then shim it with some pieces of tape.
Here's the DXF file:
where can I find out more about using the G55 fixture?