sly's BvS DOJ Build
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sly's BvS DOJ Build Expand / Collapse
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Posted 3/21/2018 3:02:02 PM


Supreme Being

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Last Login: 2/1/2024 7:08:20 PM
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Alright, everything aligned and now ready to mill something.

Batmobile

CNC RouterParts Electronics module is expensive but worth it!

Batmobile

Actual router is installed on Z axis. It is a Makita RF1101 variable speed. It's suppose to be one of the quietest models available.

Batmobile

The Back of the machine. Need to get or make some chain cable guides.

Batmobile

Final location in the garage. looks like it will work fine here.

Batmobile

Batmobile

And the videos I promised. Not great quality but maybe you can see something: (copy link and paste in your browser)

http://tinypic.com/r/33ku7g9/9

Post #160459
Posted 3/23/2018 7:08:36 PM


Supreme Being

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Last Login: 2/1/2024 7:08:20 PM
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Made the first test run today. Got a 3d version of the BvS logo off of thingverse and set it up to run. The machine worked fine but the only router bit I have is 1/4 inch which turned out to be way too big for this mill. Still, it was cool to see the machine move and maneuver on it's own.

1. The width of cut was set for aluminum or wood. That made it take quite some time for this small project. I think for foam I can set the cut width to take most of the bit instead of just the edge.

2. Need to make some kind of dust shoe to hook a shop vac to. The amount of "foam dust" was not nearly as bad as i thought it was going to be, but still, would be nice to suck it up as it happens.

3. Gotta go buy some bits............and some clamps for the slot table.

Batmobile
Batmobile
Batmobile
Post #160464
Posted 3/23/2018 7:21:20 PM
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Last Login: 12/4/2023 11:08:55 PM
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Quite impressive for a first attempt.
Long shank mills are available for high speed deep Z milling in foam.
http://www.ricocnc.com/products/248-Long-Foam-Cutting-Tools-EPS-Foam-Milling-Router-Bits-Ball-End-and-Flat-End.html
Long Foam Cutting Tools EPS Foam Milling Router Bits Ball End and Flat End
Model: Ball End and Flat End Long flute foam cutting router bits
These long series foam end mill and ball nose router bits are widely used with robot milling machine and huge CNC router which used to cut molds from EPS foam, polyurethane foam, eva foam, plastic, etc. The long foam cutting tools are great for extended reach machining, deep foam cutting, cnc sculpting big items, cnc routing foam. They are helpful mills for building cnc foam moulds and for advertising signs making.
Long Foam Milling CNC Tools Features:
1, High Speed Steel (HSS) hardness: HRC 61-64.5°
2, Sharp spiral blade for clear smooth finishing (4 flutes or 6 flutes or 8 flutes)
3, Extended Reach for deep foam cutting, carving and milling
4, Foam milling bits size could be DIY customized
Ricocnc can supply round end (ball end) and flat end (End mill) foam mill bits:
Diameter: 6mm, 8mm, 10mm, 12mm, 16mm, 20mm, 25mm, 30mm, 32mm, 40mm, etc.
Foam tools cnc, foam mill bits, long foam cutting tools, Ball nose EPS router bit, Long tools, mill foam, foam milling router bits, foam milling bits, polyfoam cutter, EPS router bit, long router bits, big cnc router bits, eps foam cutter, eps milling
vertigo
Post #160465
Posted 3/24/2018 9:21:39 PM


Supreme Being

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Last Login: 2/1/2024 7:08:20 PM
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Thanks for the link Vert.
Post #160469
Posted 4/3/2018 8:48:02 PM


Supreme Being

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Last Login: 2/1/2024 7:08:20 PM
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Just a little progress report.

I have been working with the software involved in CNC Milling and slowly gaining some ability to understand it. Now I have separated out the main body (the part you see in my avatar) and have split it up into panels that will fit on my machine. Using 4" thick foam board I am now ready to begin milling the first section of the body. (There are six sections lengthwise and each of these sections is then divided horizontally into however many sections it takes (4 or 5) and then sliced into 4" thick pieces.) Simulated runs look good but it's going to take quite a bit of time to mill this. Fortunately I can get it started and it pretty much runs it's self. So I can go do something else while it runs.
Post #160492
Posted 4/11/2018 9:56:51 PM
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hey sly,
Looks like a plan to me.
What kind of foam did you end up using, who is your source, and what does it cost?
I'm sure others planning to and/or actually building Bat Vehicles could benefit from this information. vertigo
Post #160500
Posted 4/12/2018 10:57:50 AM


Supreme Being

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Hi Vert!

The foam I will use is the 2" pink stuff you can get at any big box home store or lumber yard. Lowes and Menards sell it for $21 a 4x8 sheet. I am not going to reduce the size of the car this time so it will be true 1:1 size. That makes the sections about 18" wide. I can get 5 boards out of a sheet of foam. There are about nineteen 4" thick panels in each section. (although some will be shorter so I may be able to do better than that.) So that's about 8 sheets per section for a total of about 48 sheets for the entire body at a cost of about $1,008.00. Should be fun.
Post #160502
Posted 4/12/2018 12:56:12 PM
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I will be looking forward to your progress with this method. vertigo
Post #160503
Posted 4/13/2018 8:37:51 AM
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Last Login: 8/21/2023 11:30:18 AM
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read through the whole thread... awesome pre-production work there sly! Can't wait to see the foam version build. But with already going the reduced dimensions path for making a road driving version why aren't you continuing that direction?
In mapping out my own build I've found that an 8/10 and even 7/10 scale will get you into a general road usable vehicle, while still giving the movie car's presence.
I've found out that just renting and transporting the actual BvSmobile for a SEMA weekend display costs more than my projected budget for building my own road-worthy version. Due to the 12' width it takes a wide load hauler and accompanying vehicles to get it to any location.
In a scaled down version you'd be able to spec road legal tires and save literally a ton worth of weight in tires/wheels alone.
Post #160508
Posted 4/13/2018 6:33:18 PM


Supreme Being

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Last Login: 2/1/2024 7:08:20 PM
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Hi THEMAN, glad to have you here.

Yes, as you are aware, my wooden mockup showed that a small reduction in size works well and can keep the car width within the 8' 6" goal that was set. The full size body alone without wheels etc. is only 16' long but 9' wide from jet air scoop to jet air scoop.

I have not totally given up the idea of reducing the size of the vehicle, I just want to look at this to see the scope of it.
Post #160513
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