Medium
Story:
The last thing I knew I'd eventually have to do after Converting my Manual Gare Kiln to PID Controller Programmable Kiln was to install two SSR heat sinks, one for each SSR. I was contemplating buying some online which I could have done for about $30-$40 each, but since I already had a foundry and a mill I decided to cast my own blanks and then use my mill to cut the fins into the block of aluminum.
Little did I know that I was going to learn MANY, MANY, PAINFUL lessons during the process.
Lesson #1: Sharpen your slotting saw
Lesson #2: Don't use staggered tooth slotting saws on an under powered mill
Lesson #3: If you have to do #2, take light cuts
Lesson #4: Take light cuts
Lesson #5: Take light cuts!
Lesson #6: When the milling saw starts cutting with harmonics, FOR HEAVEN'S SAKE, TAKE LIGHT CUTS
Lesson #7: Fixing your lathe/mill with your lathe/mill is amazing
Videos:
Pictures:
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| This is the heat sink I'm aiming for |
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| Currently I have the SSR modules mounted on a 1/4" piece of aluminum |
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| The kiln with one of the aluminum pieces visible |
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| A block cut from a regular 2x4 |
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| My son helping me (cast his McDonald's toy) |
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| The mold |
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| Another attempt (the first one didn't turn out) |
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| Sifting some green sand over the wood patterns |
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| The completed mold ready for pouring |
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| Cleaning up the rough surface of the cast |
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| One side done |
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| Another view |
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| The measurements I calculated using AutoCAD |
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| About half-way done with the slotting saw |
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| Another view |
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| Another view |
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| Another view |
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| The finished heat sinks. The right one got mangled pretty good (see lessons #1-6 above) |
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| Another view |
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| The finished (good) heat sink |
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| The finished kiln with the two heat sinks |
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| Side view of the heat sink |
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| Another view |
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| The kiln heating up |
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| The PID controller which controls the SSR relays |
Tools:
Metal lathe & accessories
DIY Kool Mist System For Lathe And Mill
Adjustable wrench
Aluminum foundry
Propane burner for foundry furnace
Ingot mold for aluminum
Screwdriver
Materials:
2 lbs aluminum
Dykem layout fluid
Cost:
$0
Time:
Way too long, but the fact I had to fix the 24-tooth gear in my mill head didn't help
Savings:
$80 bucks
Conclusion:
The second one turned out really nice, but boy, did that project take long!!!
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