The AirExchanger Bottom Base
The two shroud base components will be assembled later. The brush is attached to the bases to form the shroud/show as shown here.
The dust shroud/shoe attaches to the AirExchanger via the 5 magnets you installed in the magnetic base.
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 28, #6-32 x 5/16” machine screws.
Feeds and Speeds
I used a 1/8” up-spiral two flute end mill with a 5/8” cutting depth.
Shown here I have secured my sheet stock and backer board with a series of table clamps.
I used a piece of MDF, 8” x 10” x 1/2” as a backer board. Notice that this is the same size as the sheet stock I used for the parts.
I start by drilling the 28 mounting holes through the sheet stock.
I use a 7/64” drill bit to drill pilot holes into backer at each hole.
I add a piece of tape to set the depth I need to drill. Use one of the 5/16” machine screws to help.
A 6-32 x 5/16” machine screw is snugly inserted into all the holes. These will hold the base and cutouts in-place while it is cut.
I then machine the profiles
I remove the protective cover and use my finger nail to remove any burrs.
The Finished Shroud Base
Your AirExchanger shroud base components are complete. Set aside until you start the AirExhanger shroud assembly process.