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  1. Markwalle17's Avatar
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    Jul 30, 2017, 5:21 AM - Re: My Wall-E Build Log #101

    Lightening the front sprockets for Wall-E. Using a Tungsten carbide tipped hole saw running at 220rpm on 550watt drill press. Little bit of cutting oil was used.
    Last edited by Markwalle17; Aug 5, 2017 at 7:23 PM.
  2. Member Since
    Nov 2014
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    Jul 30, 2017, 11:26 PM - Re: My Wall-E Build Log #102

    What kind of drill press? One of them fancy ones at George Henry? Looking good as always.
  3. Markwalle17's Avatar
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    Jul 31, 2017, 12:42 AM - Re: My Wall-E Build Log #103

    Apotheosis said: View Post
    What kind of drill press? One of them fancy ones at George Henry? Looking good as always.
    Tooline DP356B, ZQJ4119K, 356mm. Just a china drill press that get re-brand and painted different colours for different company's that sell them.
    http://www.tooline.co.nz/products/to...ecs/dp356b.pdf
  4. Markwalle17's Avatar
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    Jul 31, 2017, 4:04 AM - Re: My Wall-E Build Log #104

    The drill press I am using. Need to get a table for it.
    Click image for larger version. 

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  5. Member Since
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    Jul 31, 2017, 6:26 PM - Re: My Wall-E Build Log #105

    Specs say it ways over 80kg.. htf do you lift it onto a table? I'm looking at a tool line brand table belt sander. You happy with the brand then? Seems to be good and solid construction in your video. But that's not the entry level model either though..
  6. Markwalle17's Avatar
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    Jul 31, 2017, 7:16 PM - Re: My Wall-E Build Log #106

    Apotheosis said: View Post
    Specs say it ways over 80kg.. htf do you lift it onto a table? I'm looking at a tool line brand table belt sander. You happy with the brand then? Seems to be good and solid construction in your video. But that's not the entry level model either though..
    Yeah its a heavy mother of a thing. it and be taken apart into 3 parts. I had to get another person to help me move it around int shed. I have the Tooline belt sander with disc sander on it. Goes good and been using ti to square the ends of the tubes and box steel. Also is good for de-burring stuff.

    MODEL # BD-46C BELT AND DISC SANDER
    Last edited by Markwalle17; Aug 1, 2017 at 4:12 AM.
  7. Markwalle17's Avatar
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    Aug 1, 2017, 4:31 AM - Re: My Wall-E Build Log #107

    Started lightening the drive sprockets today.

    Centering holes done.
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    Pilot holes done.
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    12mm jobber drill bit.
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    All the 12mm holes done.
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    Tomorrow I will start on drilling the 40mm holes.
    I have uploaded a video of the 12mm hole drilling.

  8. Markwalle17's Avatar
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    Aug 2, 2017, 3:48 AM - Re: My Wall-E Build Log #108

    Finished 1 drive sprocket tonight. Very slow going on the big holes.
  9. Markwalle17's Avatar
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    Aug 3, 2017, 3:52 AM - Re: My Wall-E Build Log #109

    2nd drive sprocket finished tonight. Very slow drilling 6x 40mm holes in 12mm steel.

    Bearing housings
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    Idle sprocket hubs.
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    Front sprocket hubs.
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    Drive sprocket hubs.
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    Perfect fit. Will be welded in the groove.
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    Tomorrow night after work I will get another drive sprocket drilled.
  10. joberg's Avatar
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    Aug 3, 2017, 8:21 AM - Re: My Wall-E Build Log #110

    Looking good; keep up the great work!
  11. Markwalle17's Avatar
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    Aug 4, 2017, 4:05 AM - Re: My Wall-E Build Log #111

    Thanks. got another drive sprocket lightened tonight. got the weekend off so I will get the last sprocket done and get some photos and see how much lighter it is.
  12. Markwalle17's Avatar
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    Aug 5, 2017, 12:14 AM - Re: My Wall-E Build Log #112

    De-burring the holes.
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    All the drive sprockets done.
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    Nice bits of steel from the drive sprockets. Will come in handy for something.
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    All the metal from all the drilling on the sprockets.
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    Lightened 788g. It was 1.778kg. That's a total of 3.512kg lighter for the 4 sprockets.
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    Perfect fit.
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    Will be welded in the groove.
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    Looking better.
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    I have uploaded a video of the de-burring of the holes.
    Last edited by Markwalle17; Aug 5, 2017 at 12:56 AM.
  13. Markwalle17's Avatar
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    Aug 12, 2017, 1:45 AM - Re: My Wall-E Build Log #113

    Last two nights I have been working on the motor drive sprockets.

    I had to make an adapter for the centre of the sprocket so I could centre the hole saw in the sprocket for drilling the hole for the hub.
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    I then drilled a hole in a board to put the adapter into.
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    Now I can put the sprockets on and have a centre hole for the drilling.
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    28mm tungsten carbide tipped 28mm Hole Saw.
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    Drilled the mounting holes to hold the sprocket onto the hub.
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    Drilled the centre hole for the hub.
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    Fit perfect.
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    Both drive sprockets fitted.
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    I also made the plates for holding the clear acrylic for when I make the lenses for the eyes. I will have photos of this tomorrow.
  14. joberg's Avatar
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    Aug 12, 2017, 3:57 PM - Re: My Wall-E Build Log #114

    Very nice and precise work...well done
  15. Markwalle17's Avatar
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    Aug 12, 2017, 11:33 PM - Re: My Wall-E Build Log #115

    I got the clear acrylic for the lenses yesterday that I need to cut the sheet down to squares to fit into the 2 plates.

    Photos of the plates for making the clear lenses for the eyes.
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    The step is to set the reducer into when I'm vacuum forming the lens.
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    T nuts installed on back plate. Need to get some bolts for them.
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    I will be doing the lens like in this video at 3.44
  16. Member Since
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    Aug 13, 2017, 2:34 AM - Re: My Wall-E Build Log #116

    Looking good as always. The vacumn formed lenses are two pieces one convex and the other concave per eye?
  17. Markwalle17's Avatar
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    Aug 14, 2017, 12:26 AM - Re: My Wall-E Build Log #117

    Apotheosis said: View Post
    Looking good as always. The vacumn formed lenses are two pieces one convex and the other concave per eye?
    just lens in each eye. I guess you would call it convex
  18. Markwalle17's Avatar
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    Aug 14, 2017, 5:32 AM - Re: My Wall-E Build Log #118

    I have drawn up the inner eye details for Wall-E tonight. Drawn up in vector so they can be scaled to any size without loosing quality. I will be printing them on a high tack signage vinyl that will also be cut to size on the printer to fit onto the plastic part in the eye.

    Click image for larger version. 

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  19. Markwalle17's Avatar
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    Aug 19, 2017, 7:50 PM - Re: My Wall-E Build Log #119

    Clear plastic cut to size ready to make eye lens.
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    Got the bolts for the lens plates
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    Test version of the eye detail stickers.
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    Looks good. Fits perfect.
    Click image for larger version. 

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  20. Markwalle17's Avatar
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    Aug 19, 2017, 11:17 PM - Re: My Wall-E Build Log #120

    Today I spent a little bit of time working out the lower roller wheels. Bolts are only temporary.

    Plates for the lower roller wheels.
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    Working out the width of the plates and wheels.
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    Bolts will be replaced with axles.
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  21. Markwalle17's Avatar
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    Aug 26, 2017, 2:55 AM - Re: My Wall-E Build Log #121

    Got into the shed today and made some axles for the lower roller wheels.
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    Worked out the final size of the wheels today. Now to have them made out of rubber and bushing.
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    Axles made.
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    Got a new tool today. Tube notcher.
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    My work area.
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  22. joberg's Avatar
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    Aug 26, 2017, 8:09 AM - Re: My Wall-E Build Log #122

    Wow, lots of work there...new tools are always good to have! Keep up the great work
  23. Member Since
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    Aug 26, 2017, 8:08 PM - Re: My Wall-E Build Log #123

    I always wondered how that was done. You will be able to open your own custom chopper shop soon.
  24. Markwalle17's Avatar
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    Aug 26, 2017, 8:43 PM - Re: My Wall-E Build Log #124

    Apotheosis said: View Post
    I always wondered how that was done. You will be able to open your own custom chopper shop soon.
    LOL mmm chopper. GET TO THE CHOPPER. oh wrong type of chopper. Yeah I would say some people use them to make motorcycles. There is also other types of notchers.
  25. Markwalle17's Avatar
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    Aug 26, 2017, 8:54 PM - Re: My Wall-E Build Log #125

    Got the roller wheels mounted up today.
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    Roller wheels sitting in the middle of the track.
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    Lots of clearance.
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    Video of the lower roller wheels.
    Last edited by Markwalle17; Aug 26, 2017 at 9:53 PM.

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