The AirExchanger magnetic base. Note that this one still has its protective plastic skin.
The magnetic base is mounted under the bottom base.
The magnetic base has magnets installed so that the shroud assembly can be held in-place.
Drawing Files
Here is the drawing file I used to import into my CAM software.
It is in the EPS format as that is what I used to move the shapes from CorelDraw to Vcarve Pro.
Material
I used a piece of 8” x 10” x .093” polycarbonate sheet stock. These can be purchased at any home center.
In addition to the plate stock you will need a piece of waste stock. (see below)
You will also need 22, #6-32 x 5/16” machine screws.
You will also need some special magnets sized for the holes.
5, Magnets .394” in diameter and .075 thick. You can find a set of magnets here:
Set of 5, AirExchanger Magnets
Feeds and Speeds
I used a 1/8” up-spiral two flute end mill with a 5/8” cutting depth.
Feed: 50IPM
Plunge: 35IPM
RPM: 13000
DOC: .03”
Step 1
Shown here I have secured my sheet stock and waste board with a series of table clamps.
I used a piece of MDF, 8” x 10” x 1/2” as a waste board.
Steps 2 - 4
Don’t place screws into the holes that are not marked or your bit may crash into the screw heads.
Just like the previous components, I machined the mounting holes, Drilled the pilots for the screws, then added 22 #6-32 x 5/16” machine screws to the holes shown here:
Step 5
I then machine the inside cutouts and outside profile.
Remove the protective covering and clean the burrs with your finger nail. You can also use a small file.
Important
Leave the outside of the stock attached and clamped into place, you may have to come back and enlarge the magnet holes.
Step 6
Place the finished magnetic base on a flat surface. Using a mallet, tap a magnet into one of the holes. Once the magnet is partially inserted, place a #6 hex nut on top of the magnet and drive it until the bottom of the magnet is flush with the bottom of the magnetic base.
This will leave a slight depression on the top. This depression will act as a guide for the screws on your shroud.
The Finished Magnetic Base
Your AirExchanger magnetic base is complete. Set aside until you start the AirExhanger assembly process.