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LongMill Brushey Dust boot V1

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drewgraham80

@drewgraham80_112715

Dustboot for the LongMill. A remix of the Sweepy 2.0 that does not comprise, with no reduction in cutting area!

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Aktualizacja u źródła: 7 paź 2021

Informacje o modelu

Źródło: Printables
Kategoria: Tools
Licencja: Creative Commons — Attribution — Noncommercial — Share Alike

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LongMill Brushey Dust boot V1

Dust shoe requirements (in no order):

Dust shoe that does not require me to lose cutting area
Easy on / off for bit change
Travels with spindle
Good dust suction / collection
Allows me to have enclosure door closed
Easy to replace parts if damaged

Prelude – Design & referenced ideas / models:

TL;DR – Scroll to Required Hardware

I own a 3030 LongMill CNC, designed by Sienci Labs (https://sienci.com) based in Ontario Canada. I come from a cabinetmaking background, primarily CNC programing and machining. I’ve worked on large industrial machines (Biesse’s & Morbidelli’s) to smaller ones like ShopBots. When the 3030 LongMill came out on Kickstarter I knew I had to have one in my home shop and being able to support a Canadian company was an added plus.

This project came about because I was looking for an effective dust collect shoe that did not reduce the machines cutting area. The product available through Sienci Labs was effective but the whole dust shoe it had to be taken off every time I wanted to change a bit and it also reduced the 762mm cutting space by 33.5mm to 728.5mm. Not a huge amount but with a cutting capacity of 762mm I wanted to make ever millimeter count.

Enter Carbide3D’s Sweepy 2.0 dust shoe! Compact, easy to attach an detach, a great solution. However, the Sweepy 2.0 was “the perfect dust shoe solution” I was looking for. I have built an enclosure around my LongMill to help reduce noise and control dust. Installing the at 90o to the X-axis of the LongMill meant I wouldn’t be able to close the doors to my enclosure. If the Sweepy was installed parallel to the X-axis it resulted in a cutting space reduction. Another item is that I did not really want to pay for the USD – CAD conversion or for Canadian shipping.

In the beginning of 2021, I purchased my first 3D printer, a Prusa Mini+. I began by printing storage, widgets, shop solutions for around our home, shop and trailer. Also lots of Pokémon for my 2 boys. I came back around to redesigning a dust shoe solution and eventually created a remix using Billy_12341’s design on thingiverse (https://www.thingiverse.com/thing:4391144) as my starting point.

The primary focus of my remix was to reduce the size of the dust shoe. The challenage with reducing the size is that if you make it too small you will lose too much air flow, not get enough suction and end up with an ineffective dust shoe. Then I stumbled across Cosmas Bauer a Youtuber/ maker / woodworker from Germany https://www.youtube.com/c/CosmasBauer. I Stumbled upon his two YouTube videos about improving dust collection on handheld routers and 3D printing.

Cosmas Bauer’s R&D was simply, amazing. His videos showed how something as simple as a piece of tape can improve the dust collection of a router. I applied these concepts to my dust shoe design. The resulting dust shoe was now small enough to fit my design constraints, did not sacrifice any cutting space, allowed the doors on the enclosure doors to close and effectively collect dust when cutting with the LongMill CNC.

Figuring out how to replace the bristles on my dust shoe came by when I was removing the bristles from the orginial LM dust shoe, and I released how hard it was to remove. I further improved my dust shoe design by creating a two-part solution for the lower section of the dust shoe. A few test prints and I was able to capture the bristles in the 3rdpiece of the dust shoe.

The LongMill Brushey Dust shoe was now born!

Required Hardware:

Magnets - https://www.leevalley.com/en-ca/shop/hardware/rare-earth-magnets/magnets/disc/32065-rare-earth-circular-magnets?item=99K3203

Metric Socket Cap Screws - https://www.amazon.ca/NINDEJIN-Socket-Screws-1060pcs-Assortment/dp/B07PHYJ8BB/ref=sr_1_1?dchild=1&keywords=NINDEJIN+M2+M3+M4+M5+Alloy+Steel+Socket+Head+Cap+Screws+Nuts+Set+s+Carbon+Steel+Screws+Assortment+Kit+%28Socket+Head+Cap%5B1060pcs%5D%29&qid=1633549871&s=hi&sr=1-1

Flexible Brush Strip – If you have a 3030 Longmill the brush strips from the dust shoe will work. If you need to purchase something like this may work. Test fitting may by required. https://buildyourcnc.com/item/strip-brush

3D Printing

All parts were be printed with a 0.15 of 0.20 layer height and a 15-20% infill using a 0.4 nozzle. All parts printed with PLA but PETG could also used as well. The pause times and Z-heights listed below are for a 15% infill and 0.15mm layer height.

These models are designed for use with a router with a diameter of 65mm. If your router is a different size, please scale or adjust using the provided fusion file. My file is by no mean perfect)

Top Section

the top can be printed without supports or a raft. The print is paused around the 45 minutes / 3.8mm Z-height to allow the first 4 magnets to be inserted. Use a bit of CA glue and make sure all the magnets are the correct direction before resuming.

Mid-Section

The mid-section requirs the use of supports and has 2 pauses. The first pause is to place 5 M4 nuts into the print for the mid & bottom sections to be screwed together. If you use “For support enforcers only” with paint on supports, make sure to check your sliced model as it will put supports where you are going to insert your M4 nuts and magnets.

M4 nuts – 2 hours 15minutes / 10.25mm

Magnets – 5 hours 5 miuntes / 30.80mm Make sure the magnets go the correct way or the top will not connect. CA glue the magnets as they get no holding power from the magnetic bed.

Bottom Section

Printed upside down. No supports or pauses

Air Vent

No supports or pauses. This will only fit with the Makita RT0700C router. This insert can be modified for other routers. I downloaded a model for my router from Grabcad.com https://grabcad.com/library/rt0700c-tupia-710w-makita-1 designed by Adeboot Engenharia

Dust hose connection

These parts require no supports, but a brim is recommended as they have a small contact area. Make sure the sloped side of the upper section of the dust hose connection is on the opposite side of the aligning slot. You should have one side that is pretty flat once they are together, and the other side will be on an angle outward. The flat side will go against the router mount on the CNC.

Assembly

Start by taking 2 washers, 2 nuts and the 2 longer 12mm M4 screws and the printed top section. The nuts and washer should be a snug fit and require a little bit of pressure to fit into place. If needed use a longer screw to pull them into place. Loosely screw in the screws. Thread locker is recommended here as the motor will produce vibrations.

Next, the flexible strip needs to be more flexible. Start by scoring lines with an x-cato knife about 6mm in width apart from each other along the length of the strip.

Using two pairs of pliers, gently place one on either side of the scoring line one one side of the strip then break the flexible strip at the score line. Be very careful not to snap the strip into two pieces. Continue around the stirp until it looks like the last photo below.

Gently slide the now curved flexible strip into the middle section of the Brushey. Make sure to keep one side the plastic strip under the retaining ring of the middle section. Keep sliding the strip in until it gets all the way around. Mark and cut the strip the goal is to get as close to a full wrap as you can. Mine ended up being around 220mm completed.

After the brush strip is the correct length and installed into the middle section, garb the bristles with one hand and slip the bottom section over them. Be careful not to miss any of the bristles. If you do miss some bristles, simply push them through the bottom section. Once that is done place the remaining washers into their places and secure the bottom to the middle section. The part will be referred to as the lower section of the Brushey.

To install the top section onto the router put the top & lower sections together (hopefully you put the magnets in correctly) the magnets will align everything and snap together. Install the now assembled Brushey onto your router and push it up until it cannot go up anymore. The bottom of the top section should be flush to the bottom of the router.

Time to connect the dust hose pieces together. Test their fit prior to adding glue. Once you are happy with the fit, add some CA glue and glue the two pieces together. Attach your 2.5” hose to the top of the dust hose connection with a band clamp. Be careful not to over tighten, as it will crush your dust hose connection

Once you have all of the other parts installed you can choose to insert the optional air vent. I noticed a huge difference in performance, for the better when the air vent was installed. It’s simple. The air vent has 4 tabs, and the lower section has 4 slots. Align the tabs and slots and gently push the air vent into the lower section. It’s a tight fit by design. I had to file mine down just a bit. I did that on purpose as I wanted to make sure it did not come out easily when removing the lower section of the Brushey. The air vent is dependant on the position of the router and can only be installed one way. The router needs to be positioned into the Longmill so the power cord comes out of the left hand side when looking at the machine. Some adjustment may be required.

This photo shows the 3030 Longmill in the lower left-hand side of the bed with the coordinates of 0,0 in X & y and then the machine at the max X-axis travel of 785mm. The LongMill magnetic Dust shoe reduces the travel by 33.5mm and they have a recommend cutting size of 762mm along the X-axis. Brushey gives you a cutting area of 785mm along the X-axis.