Chevalier 2040 CNC Bed Mill Restoration

[coolidge]

11/29/2024 - That's a wrap for today. 5 hour RT in the morning to pick up a pallet jack capable of lifting this thing.

1. Each Y box way measures 5.5 inches across.
2. Total width across the Y box ways is 22 inches.
3. The saddle is 9 inches thick
4. The saddle is 49 inches long
5. Confirmed both the saddle and table have Turcite.

Completed

1. Got all the chips and nasty grime cleaned out of the chip pan.
2. Removed the right aluminum table end tray. The left tray is missing.
3. Removed the left rear chip backsplash. The sheet metal is pretty heavy and thick enough that they tapped holes in it.
4. Cleaned and removed both Y way covers. They are surprisingly still in good shape. I'm guessing they were replaced at one point.

Tomorrow

1. Remove the chip pan (it's all one big piece) and right rear chip backsplash.
2. Clean the monster table T slots and coolant channels
3. See what I'm up against, apparently there's a coolant pump and reservoir.
4. Remove the X and Y servo covers so I can rotate the screws and move it around for cleaning.

 

[coolidge]

FREE tooling, inserts and measuring tools?? I'm cashing in all my Karma this week. So I drive up to pick up the pallet jack from this gentleman. I had sent him a pic of the mill I'm buying the pallet jack to lift.

While loading he told me his father owned a manufacturing business for 40 years making stuff for CAT and Pape. Apparently the bolt-on bits that cut/break concrete. They had a bunch of Okuma's, 40 employees yada yada. Pretty cool.

So I'm about to back out and leave and he knocks on my passenger window...he says he's got a bunch of tooling, inserts and measuring tools from when his father passed away and they had to liquidate the business. 2nd wife estate drama had taken place. He says he has a bunch of the tooling, inserts and measuring tools and would I like them for free?

also and

 

[coolidge]

Working the graveyard shift on the mill tonight. I got the chip pan and backsplash removed. Front Y servo motor cover removed. Now cleaning the nasty chip/coolant channel around the base. I see liquid through the screen so something needs pumped out. Looks like cutting oil.

Oddly, I have yet to encounter a chip that's not aluminum. If it only cut aluminum that would be a good thing.

Today's AHAHAHAHA moment...the servo motors are 2HP dang!

 

[coolidge]

Found a source for the 24mm x 1.5 x 80 leveling bolts! I have the 6 originals but they are rusty, just easier to buy 6 new ones that are nickel plated, ordered!

 

[400bird]

Your servos are rated the same as my spindle, free tooling, etc
Sometimes everything goes well, congrats. I hate you

 

[coolidge]

Your servos are rated the same as my spindle, free tooling, etc
Sometimes everything goes well, congrats. I hate you

I know right. When I looked up the specs I was surprised at 2HP though they are rather LARGE servos. I thought, maybe it's because they were made in 1996 but it's just that they are 2HP. Now I'm hoping I can use them. Though they are brushed servos. I think brushless is all the rage these days.

In not so good news the Clearpath all in one servos to replace these are $1k a pop x 3.

 

[coolidge]

In good news, there's a video of someone who retrofitted this exact mill with Mach4 and upgraded everything. Watching it I was disappointed as it was slow as a snail. I thought, is it really that slow? Turns out the guy used steppers with a max rapid of like 93 inches a minute, phew! The specs in the books that came with the mill say 200ipm on Z and 300ipm on X and Y.

 

[Karl_T]

AMC, Advanced Motion Controls, made great DC servo amps in that size. They can be found on eBay very inexpensively, but have to watch a while.

here's model #s. Pure guess on my part, you need 25 amp max current. An oversized unit will work too. Double check your control does +/- 10v control.

 

[coolidge]

Success! Was a bit nervous about getting this drill chuck out of the spindle but a couple of whacks with a plastic dead blow and easy peasy. That's one beefy drawbar, looks to be 5/8. Confirmed it's a Kurt power drawbar on top of the head, malfunctioning and missing it's cover. I'll be ordering a new one.



Confirmed the large holes in the side of the column are for holding up the counterweight. There are matching holes in the counter weight. I shoved a couple 1 inch steel bars through, raised and rested the head on a wood block to make some slack in the chain. Now this whole nasty chip grease packed mess is about to get unbolted for long overdue cleaning. ZZ Top La Grange engaged!!

 

[coolidge]

What do we have here a comedian private Pig Sty



Wow



Much better