Ron:
When I look at your E-stop wire strain-relief/panel bushing, I wonder if it might work better to design your toolpath to include small support tabs between the two bushing halves, along with moving your existing support tabs closer to the centerline between the two halves. You could also reduce the size of your supports without losing inducing much more flex. Making these changes should provide sufficient support to the two parts during the machining process and it should help prevent the parts from tearing away before machining has been completed. I'm not sure if the software you use to design your parts and toolpaths will allow you to make these changes, but I expect that it should.
I've attached a simple 3D model showing this suggestion.
I must say that I am not a model builder, per say; however, I've been making lots of very intricate things using CNC technology for many years. I stumbled upon your project while searching for saw blade to fit Jim Byrne's model saw. I purchased my JimSaw more than five years ago; however, I am ashamed to say that I have never even made a test cut using this saw. There have been too many other things that have distracted me along the way - mainly my CNC routers. These machines are the most useful (and used) tools in my shop! When they are designed, built and calibrated properly, they can be used to make absolutely perfect parts . . . almost regardless of part size or complexity.
I am fascinated with your build log and will continue to follow your updates.
Good luck with your ongoing build!
- SpindleJockey
