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CC machine spindle 2005

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Well, I finally wore out the spindle on the IG-88 CNC mill. Those cheapo skate bearings that I've been

using can't handle the constant high-speed abuse of a cnc mill. So, I decided to search around for betterbearings and parts that would require minimal machine work to get a more reliable spindle. This is what Ifound.

I started off with a piece of 1.25"OD .825"ID cold rolled tubing from Online Metals. This stuff is justgreat. It has a wall of almost .2", which makes it real tough for a spindle housing. I then searched for highspeed flanged bearings that had a .825"OD. It only took a few light passes on the lathe to get the ID of the

tubing to the correct diameter to fit the bearings.

A 12" piece of this tubing was only about $10, so I cut the piece in half so I could make two spindles.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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These bearings are almost a perfect fit for the tubing. With minimal work, the bearings snug right intotube.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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A real nice high-speed spindle is on the way! I just might be on to something here.

Ready to machine the shaft!

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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Here you can see the parts layout. There really isn't that much too this thing. Sometimes simple is better!To make the shaft, I used a piece of 3/8" air hardened drill rod from Enco Tools.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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Here you can see how a 1/8" solid carbide end mill looks next to the shaft. I bored the 1/8" hole toprecision tolerances with a 1/8" carbide reamer. An allen set screw holds the end mil in place.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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Only one threading operation is needed to hold the entire assembly together. I used a 3/8-24 Nylock nut tokeep things in place.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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The drive end of the spindle is quite simple. Just a nut, bearing, and pulley.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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I picked up these bearings from BearingsDirect.com. They are part# FR6-ZZ and will cost you about $5each.

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On the work end, a simple e-clip arrangement keeps the shaft and bearings locked in place. The nut on theother end takes all of the slack out of the system and tightens the bearings against the housing.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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How nice everything fits together! Of course this is the 5th spindle that I've made, so I've had my share ofmistakes!

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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I stole the aluminum pulley from the old spindle, so I didn't have to make this part again.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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A 1/8" solid carbide end mill installed and ready to test for runout.

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html

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All assembled and ready to fit up the motor mount!

C machine spindle 2005 http://www.buildyouridea.com/cnc/spindle_05/spindle_05.html