So here's an update in my experience using the mill so far. I broke the belt that came with the conversion kit, but luckily I had noticed it starting to fray and I got on Amazon and ordered 3 more. I had noticed that the belt had a deformation in it right out of the box. It didn't seat in the pulley very well at all as a result. So what happened as I was running the mill for a few nights at work is that the lump, for lack of a better word, was clipping an edge of the clear plastic cover with every revolution. So it was loud, and it was slowly fraying. Luckily, it didn't finally break until late Thursday night, and the new belts arrived Friday morning. Once I put a new belt on, I was back in business.
I bought the mill for personal use and I figured I'd also end up using it at work eventually.
"Eventually" came less than a week after I had finished putting the DRO's and power feed on. I don't know who screwed up, but at 11AM on a Friday morning, I get a cryptic text from our GM telling me to check my email
It turns out we have a big show going into Vegas in less than ten days that involves a LOT of prep, set up, and welding. Oh, and it's all materials that I don't have on the rack, so we have to get the order in and send the new guy into Orlando rush hour in a 26' truck to go pick it up.
So instead of cutting and jigging and welding everything, I decided to do a bunch of half lap joints on the 3/4 box tube and also to notch out the pipe--I got this mill I haven't really learned how to use, right, so what the heck, let's break her in right! Less set up, less welding, less heat warp, in such a small frame I figured. And it looks much cleaner.
9 straight days of 14 hr days later, I was done at 2:30 on Sat night, the painters sprayed it all black on Sunday, and the truck was loaded and left on Monday. And my boss, the GM, (who had previously been skeptical about what having even a mini mill in the shop could do for improving our quality and efficiency) tells me that he thinks it was a GREAT idea to buy it and he will pay me a rental fee when we end up using it like I did on this job. We are a two person department, and my guy was in the weeds on another big metal job, so this was all on me. 20 column hanger frames of two sizes (and no drawing), and a bunch of other crap as well.
Here's some pics and a bit of explanation -- The white "tiles" clip together to form walls of stage decor. The frames in the pics are based on a prototype I did months ago so that they could create columns and returns, etc. They are upside down in the pics. The pipes are sleeves that fit over vertical pipe mounted to large pipe/drape bases. so they will go anywhere from 10 to 20 feet tall, with the tiles on all four sides, and be free standing. I personally think drapery pipe is a flimsy choice because the wall thickness is about a 16th inch, and I suggested that if they really want to do this right they should be going with schedule 40 inch and a half pipe.
At any rate, the mill was a workhorse! Nothing fancy here in terms of machining, but a huge timesaver and a great help. The last two photographs are of the Proto type I did a few months ago. It was thrown together out of scrap just testing the idea. When they threw the project at me we hadn't gone back to the prototype, even though I had asked if I could. So I had to scramble and come up with something that would work for an actual show with no time to speak of, so I think we did a pretty good job overall.