Chamfering Machine

[petertha]

I guess I could call this Version-2. My first attempt was a V base I adapted onto a Makita variable speed trimmer router where the cutting occurred on the end of the cutter, which was my preference. It worked OK but it had a few issues. It was kind of gangly to mount & also not super safe to hold with one hand & push the work through with the other. The depth control used the ratchet wheel & clamp, but it was kind coarse & fiddly to adjust. The bigger concern was metal shavings could dropping through the cutter clearance hole & ultimately into the motor windings.

So this assembly uses my Bosch die grinder in lay down mode. Unfortunately this grinder is not variable speed but seems to work OK. This has the cutting action on the side of the end mill. Die grinder motor vents are more protected than routers by design. But the firewall, base & 2 side members kind of make a natural confined box so 90% the chips drop down safely into that natural cavity, nothing back to the motor.

To adjust the chamfer depth, I loosen the clamp handles, turn the knurled knob which jacks up the V frame up or down. The frame movement is confined by the UHMW slide rails. The base is 1/2" MDF. My original plan was to mount the MDF base to a bench top, but I decided to add a keel from same material & hold it the bench vise. A lot more convenient to quickly set up & store away.

The test cuts look pretty good. Quite smooth & consistent. The aluminum tester is about .070", the steel is about .020". You can zip through the edges pretty quick & there is no kick back tendency, it’s quite controlled.

The V rails were designed around 3/16" thickness but I realized what I had in my scrap box was under that thickness & kind of garbage mystery material from sheet metal stamping. After filing & straightening it still looked like crap so I gave it the Tremclad spray bomb treatment to prevent rust. In hind sight it’s probably going to just scratch off so maybe I’ll find some nicer material one day. Anyway, the machine turned out ok.