Russell,
That is not an uncommon problem with brush motors. It is usually from glazing that starts the problem. Your pictures do point to an odd spring. I have not ever seen one in a collapsed state like that before. Usually they are broken and purple. I know that many hardware stores carry brushes. You could also call them if you have no luck with a service center. You should be able to look in your manual and it should tell you the minimal brush length. It is usually about 1/2 of the new brush length.

Russell,

I ordered my second spindle because I don't want to be without one.

I had trouble with the speed control unit on my 5625 and the local repair place did not have any. I bought a 2nd one and extra brushes. You can never have enough spare parts.

It is a lesson we all have to learn.

also when you have enough spare parts, you can make more machines and have spare machines :D

Out of a really bad day came a great day. I was able to get the brushes from the local repair center and have some that are being Fedexed to me for free. I was back up and running in less that 30 minutes after I picked them up.

Sheets are all cut and ready for Pickup.

Milwaukee was a really nice to. Here is the email from them

Hello Joshua,
Milwaukee will replace your in-question carbon brush, part number 22-18-0075 no charge, your shipment is coming FedEx.

Donald Kucik
After Sales Technical Service
Milwaukee Electric Tool Corp.
13135 West Lisbon Road
Brookfield, WI 53005-2550
Phone: 1-800-729-3878
Email: [email protected]

It's great that they are taking care of you....

I have no idea what someone would charge to cut a panel like those... Would you mind sharing the amount you charged the customer?

By the way,,, They look great :)

Steve sent you a pm. I dont mind telling anyone just dont want to make it public. He paid well but either no one else wanted to do it or they wanted to much as he found it to be a better deal to have me do it and ship 5 sheets 540 miles.

Thanks for the info :)

Another question if you don't mind....

Looking at the picture on the left I see a lot of areas where there are dark lines but not a lot of material removed.. Are those lines cut lines or some type of marker?

The panels look great! Thanks for posting photos.

Steve they are all cut lines. I left tabs in place so it would be better for shipping. https://dl.dropbox.com/u/16437521/20...2014.18.17.jpg

how come you got so much chatter (vertical lines) on the curved cuts?
was the bit too small diameter?

Russell,

It looks like you cut 3/4" MDF - 3 sheets. Nice looking design and that was a good idea to keep the waste tabbed to ship the pieces.

Danilo, I dont think it was from the cutter as the straight lines area as smooth as a babys bottom. Its hard to explain but I never have problems with straight lines or circles. It only shows its ugly head when I cut curves like in the photo. If I had to guess it is from all the Nodes/Lines of code. I have tried turning on and off constant velocity and although they became smoother the lines like to wonder off the path a little. The photo makes the lines look huge but a quick pass of the sanding mop took care of them.

Nils, it was 1/2 MDF. If it wasnt for the tabs I dont think I would have been able to lift it off the table with out falling apart.

Russell,

I don't remember which CAM software you are using and I think all the Vectric stuff has the capability but convert you curves to Bezier Curves it will help smooth the curves.

Did you cut those panels in one pass? I was looking at the pictures and I can't tell.

V-Carve Pro and Aspire does

Nils, I have Vcarve and I think I told you or someone else here about turning everything into curves. I completely forgot myself though.

Keith, I started out with a single pass. Then the whole mess with the router and thinking I was over straining it. :rolleyes: So I went to 2 passes and never went back to change it. I just wanted it cut out before the deadline and didnt want to screw anything up.

The top sheet in the large photo is a 2 pass cut. The one below it was a single pass cut. The cutter was a .125 diameter O flute upcut endmill. My cutting speed was 100ipm with the router set for 12,000 rpm I believe.

Update. The guy was super happy with the way things turned out. He ordered another 10 sheets and is figuring out another method of shipping. He doesnt need them until August and likes the new non-rushed price even better. Here is a pic of how they turned out.
https://dl.dropboxusercontent.com/u/.../IMG_7926.jpeg

looks great... Did you make the bases for the sheets also?

Steve, I didnt make the stands but it looks like they are decorated with the scrap areas I sent for shipping.

Maybe thats another part you could make for him :)

Absolutely brilliant work!!!!!!!!!!!!!!!

Nice, I like those
:)

Does anyone have any suggestions where patterns like Rus can be found?

Keith you will want to look up Dover designs. It's just one large source. You can also look up scroll saw patterns.

Russell,

That looks fantastic. Great job.

Awesome work Russell, do a Google image search for any plan. Works most of the time.

Cheers
Tim

I was just wondering, are the panels 8ft X 4ft?

Keith they are just a little shy 44x80. I don't know why that size.

Thanks Russell

My wife is a pastry chef and used to do wedding cakes. I showed this to her and see said "Wow". It is nice to see what others do with the parts that are made on these machines. If your customer does a lot of cakes, you may have a nice repeat customer of different designs or possibly the same one if the display is part of their price.

Even for all the trouble you had with the router, there must be gratification in seeing the end product.