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Yes on replacing as a full set per axis. Pretty much bolt on with a little shiming to get square. My pick a few years ago was Hiwin. I will add more when I am on my computer.

I have and it wofked fine. I don't remember how many cycles but not many, say around 20. I have had zero isdues with stainless bolts in 6061 so no idea what yall are talking about. I would say you want a minimum of 6 to 8 segments, 4 isn't enough. Thread your holes the minimum needed to make...

My experience is Harvey makes far tougher 3 flute aluminum specific end mills than Destiny. With the right conditions I think Harvey's feeds are sound. If memory serves the right end mill for their 1/16" dovetail is .055".

A manual lathe works well for this type of work, especially for holes over 5" deep.

Smoothing maybe?

A lot depends on how it sounds IMO. If you can keep up with loading then let er rip.

+/-.005" is a tight tolerance?

Is the chamfer top and bottom? Being polycarbonate I suppose you are going to run it with an air blast. If you do want to use coolant make sure it doesn't attack it first. I don't see this as anything other than custom fixtures, and good ones at that. Any little errors in the fixture will eat...

I wonder why these aren't molded?

Vacuum is limited when holding small parts to begin with so the last thing you want to do is limit your fixture design. Can you show the parts, or die cut them?

I know that anything tighter than light preload and the block is mated to the rail, you can not get them seperatly. At least for Hiwin or THK ball ways. I wouldn't worry about the accuracy or preload too much as there are things out of your control.

Wow, my 2001 30 taper weighs 8,000 lbs. Chip to chip tcs are supposed to be 2.7 seconds too:). The one thing I don't like about my Kitamura is the table is a bit far away from the door to load parts. When you add the coolant tank in front of the machine then the closest you can get your toes is...

The tank on mine is 80 gallons, at least 500lbs, and strapped to the side of a building. For a few reasons I made my own coolant system and never regretted it. By the way I think 4600 lbs is way light. Does the coolant come out the front on your machine?

In the old days Fusion was known for having a great file converter, I don't know if that is still the case. No need to load, just convert and done.

Did you check tram/Z axis turcite wear yet? That's something to do before buying holders.

Kitamura told me to be very careful with the air/oil units as they don't like to sit. They are prone to develop air bubbles in the oil side which can block the metering units, with the top bearing unit most likely to get blocked as it supplies the least amount of oil. On my 2001 Kit the metering...

Not having a 4th limits you on this part. Do you have a tool changer or is it the manual type? Do you have the material?

I like Uruyu drivers because of the ones I have used, not many, they by far have the highest quality "feeling" of how they work. They are extremely consistent with the torque from screw to screw and a high quality Japanese air tool that should last forever with a hint of care, so great to buy...

Air powered screw drivers, hands down!!! I buy them on Ebay for 25$- 75$. I will post more about them when I am on my computer.

I think the range is 9.1-9.4. I called them up and talked with a tech about which coolant he would recommend after doing some of my own research. He suggested it since it is one of their highest ph coolants. I machine mostly aluminum with some mixed steels and plastics and so far love it. How...