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Step 2Day 2, padding and keyway modification
At this point the build was stuck since it would be another day before the 0.201" drill bit would arrive from McMaster-Carr, so I tackled two of the smaller projects.
The first was adding padding to the area the flipping attachment would contact the front panel. I used some 3/16" thick rubber cut into a hollow square shape and glued to the aluminum plate. The small pocketed area was added to allow the use of the optional low rpm dual grinding disks, as the main weapon hub would brush against the aluminum plate when spinning continuously.
The weapon sprocket needed to sit closer on the weapon motor shaft than the existing keyway allows and without a broach available, I chose to use a mini-mill with a 1/8" endmill to expand the keyway area. The shaft was clamped to the table with the existing keyway sitting roughly level. The endmill was then brought into the keyway slot and aligned with the vertical walls of the keyway. Using low spindle speeds and some cutting fluid it was easy to expand the keyway. I've also included a picture of the modified shaft next to a stock shaft for comparison.
Before calling it a day, I used some Goop adhesive to glue the bearings into the bearing blocks and the weapon hubs to keep them from sliding around while I was assembling the weapon rack.
The first was adding padding to the area the flipping attachment would contact the front panel. I used some 3/16" thick rubber cut into a hollow square shape and glued to the aluminum plate. The small pocketed area was added to allow the use of the optional low rpm dual grinding disks, as the main weapon hub would brush against the aluminum plate when spinning continuously.
The weapon sprocket needed to sit closer on the weapon motor shaft than the existing keyway allows and without a broach available, I chose to use a mini-mill with a 1/8" endmill to expand the keyway area. The shaft was clamped to the table with the existing keyway sitting roughly level. The endmill was then brought into the keyway slot and aligned with the vertical walls of the keyway. Using low spindle speeds and some cutting fluid it was easy to expand the keyway. I've also included a picture of the modified shaft next to a stock shaft for comparison.
Before calling it a day, I used some Goop adhesive to glue the bearings into the bearing blocks and the weapon hubs to keep them from sliding around while I was assembling the weapon rack.
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