Ok, so I’ve managed to get everything up and running after a few trials and tribulations (including having to put in a UPS because of big voltage drops we’re getting where we’re work - another story!) and have a linkage kit set-up. However, I’ve got problems with getting consistent profile cuts. I am cutting quite extreme profiles, i.e. almost full width (2400mm), slow arc (2060mm radius, about 100mm depth) roof spars out of 18mm hardwood ply for a project, with half-height centre slots and right-angle corners at each end. I have extended the board to support the sled at the bottom and sides, but lose the profile shape at the ends (and the centre with the top couple of spars), plus have difficulty in maintaining good slot/right angle cuts. I’m using a 6mm straight 2-flute cutter, with 4.5mm depth cuts at 800mm/min. I notice at the far left/right cuts (surprise) the longer chain goes a bit slack and the linkage drops, only to be pulled taight again when it starts cutting. I’ve messed around with using climb/ conventional cuts to try to optimise the cutting at the end, but this seems only to help so far. Should I:
- try to get a single flute cutter to get into the right chip removal rate?
- reduce the plunge depth?
- add more weight to the sled?
- replace the (smooth) MDF sled I’ve made with something else?
- go for (yet) another beer?
Ok, the last one’s a given, but any useful suggestions would be very welcome.