what my shopbot and I did this week

[Steve knight]

This took about 10 hours of work to get the design done make lots of test cuts and work out the details. The hardest part was getting the hole in top just right so the ipod rests on the back. Then getting the holes all the right size and the jig remade to a better acrylic one that really works well.
This one is purpleheart and they will be all different woods.
I only did the wood and plastic and finishing none of the wiring that goes on inside. All high end plugs and such.
It takes about 5 minutes to cut all of it and do the engraving. 3 bit changes though a ½” straight bit for the bulk of the wood removal a ¼” bit for the holes and a 60 degree vee bit for the engraving.
I am debating on changing this to vacuum. But clamps are easy and work well.
I like to make jigs like this were everything is at the same level. It makes it far easier to setup. But it is a pain to have to laminate the acrylic to get the right thickness. But that thick stuff is too costly and it is hard to find in scrap.

http://i154.photobucket.com/albums/s266/knighttoolworks/ipod%20dock/ipoddoc000.jpg

http://i154.photobucket.com/albums/s266/knighttoolworks/ipod%20dock/ipoddoc001.jpg

http://i154.photobucket.com/albums/s266/knighttoolworks/ipod%20dock/ipoddoc003.jpg

http://i154.photobucket.com/albums/s266/knighttoolworks/ipod%20dock/ipoddoc004.jpg

http://i154.photobucket.com/albums/s266/knighttoolworks/ipod%20dock/ipoddoc005.jpg
http://i154.photobucket.com/albums/s266/knighttoolworks/ipod%20dock/ipoddoc002.jpg

[Keith Outten]

Steve,

How about a picture of the finished product with an ipod installed.

The box detail is impressive. Have you thought about using Corian for the boxes, they would be awesome. I use Corian for jigs on the ShopBot , in my laser engraver and various other machines. Your right about thick acrylic being expensive, I have not been able to find a source for scrap either.

Once your in production mode how many of the boxes do you think you can machine per day?

.

[Steve knight]

corian is a good idea finding it takes some work too. these are for high end audiophiles so they have to look really good. I will get one with a ipod in it it may not be finished but you can see what it looks like.

[Rob Wright]

Steve - are the multiple cutting areas set up as "fixtures" so you have the machine automatically zero to the next cut out after you have moved the block of wood? I am having a heck of a time with saving ficture locations in Mach3 so I can consistently mount a jig in the same spot and cut the identical piece. How does the partswizard/millwizard handle this in the shopbot software?

- R

[Steve knight]

ok here is how I do it. the angled bracket made of ply is screwed to the table. I true it up with the machine. then I use the xy zero utility using a v bit and a block of wood in the jig I put the tip right on the corner of the block. then I take those figures and make a custom xy ruitine that zeros the machine then moves it to that location then zero's the x and the y so that is all done that location is always accurate. I have several of these.
then the jig I made in vcarve but it does not matter. I make the jig then I use it to locate the cuts. they are centered in the jig cutouts.
so it is very repeatable. I make the jig so the parts are all at the same height so you just use the jig to zzero and all is done and accurate.