The AirExchanger spindle mounting bracket consists of two components.
The rear mount (shown here)
The rear spindle mount is attached to the top of the top base.
The front mount (shown here)
The front spindle mount attaches to the rear mount. This provides a clamping action to secure the AirExchanger to the spindle.
Spindle Hole Size
The drawing has a 3.27” diameter cutout for the spindle. If you need to change this you will need to make modifications in your CAD software. Note that the drawing file bundle has much more detailed drawing files and Gcode for cutting all the sizes below.
Here are some common sizes I have used.
80MM Spindle - 3.15”
Makita RF1101 - 3.22”
Hitachi M12V - 3.27”
Bosch 1617EVS - 3.5”
Dewalt DW618 - 3.5”
Please note there are some differences to mounting the AirExchanger on both air and water cooled 80mm spindles. I will cover these in a different article.
I used a 2 pieces of 5” x 7” x 1/2” expanded PVC plate stock. I can get large sheets of these at my local home center. Smaller sheets can be purchased online.
I like the expanded PVC because it’s light weight and can be very forgiving to machine mishaps.
In addition to the plate stock you will need a piece of waste stock. (see below)
You will also need the following hardware:
2, #10-32 x 3/4” Machine screws
2, #10-32 Hex nuts
2, #10 Lock washers
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 work piece stock and waste board with a series of table clamps.
I used a piece of MDF a little larger than my work piece as the waste board.
I mill the rear mount holes and profiles, and do the same for the front mount.
Both the holes and profiles will be done together. I am using tabs to hold the stock in place.
I clean the edges and corners with a fine sanding sponge.
A small hole is drilled into the ends of the rear mount with a 3/16” drill bit. The holes should pass through the center of the slot.
The total depth should be about 1/2”.
The small groove on the ends is to help align the drill bit when you make these holes.
A 3/16” hole is also drilled through the ends of the front mount as well. In this case the hole goes all the way through.
Take the two #10-32 hex nuts and insert them into the slots on the rear mounting bracket.
Push the nut into the slut until the center of the nut is aligned with the hole you drilled earlier.
Insert the lock washers onto the two machines screws.
Insert the screw assembly into the holes you drilled earlier in the front mounting bracket.
Butt the front mounting bracket against the rear mounting bracket and thread the #10-32 machine screws through the front bracket and into the nuts on the rear bracket. Leave them loose.
If you have problems mating the screw with the nut, try enlarging the hole in the front mounting bracket a little.
Slip the mounting brackets over your router spindle and tighten the #10-32 screws.
You should be able to firmly secure the mounting brackets to the spindle.
If you find the brackets are too loose, take a little off the front mounting bracket, as shown here.
Remove just a little as it will go a long way at tightening the mount.
Your AirExchanger spindle mounts are complete. Set aside until you start the AirExhanger assembly process.