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Chiseling corners in MDF shaker door7/4
Wondering if anyone has any suggestions for chiseling the corners of these doors pictured with the round corner, to look like the door with the squared out corner.
In programming I can get a shaker door made off the CNC but was disappointed to find we can't get the corners squared out without an extra expense to the software to allow the Z axis to allow the router bit to pull away and create the squared corner.
It's just not viable at the moment to upgrade for the small amount of shaker style doors we do but just seems such a shame to order out the doors when we are 90% of the way there in house. Good saving and lead time reduction.
I have been researching corner chisels but see nothing that could consistently check out that corner.
Any thoughts or suggestions would be much appreciated.
i just made this door recently from 3/4" ranger board. I use a 1/8" bit to clean out the corners and a surfacing bit for the field. I'm just using Vcarvepro - no other special software.
Can't you enter a hand written program? Do you have an automatic tool changer? The time you take to hand chisel, and repair any mistakes with the chisel would pay for a software upgrade in a couple months. Well, depends on how many doors you do a month.
Why not just make an "L" shaped jig that references off the outside of the door, then use a laminate trimmer or similar small router that you can use with one hand. Put a 1/8" bit in that that has a bearing or accurate bushing and use that to hand chase the corners.
thanks for the feedback
Don't know if you can see it in the picture but there is a chamfered inner edge. I would have no problems making the door with square inside edges (looks nice by the way).
I use ezynest which is basically a skin for enroute. I don't fully understand it yet but from what I have been told I require some sort of 3D ability so I can tell the chamfer cutter to pull away from the corner as it pulls out to make the sharp inside corner which is in the version up.
This is definitely worth it for the quality of finish and single process but it's only a small run of doors and I wan't to see how they. I'm very overhead heavy and can't afford to upgrade software at this stage.
easy to do on the CNC, here is a preview image. 90 degree V bit for the profile, pocket with 1/8" bit for the corner then a larger surfacing bit for the panel. Quickly done with Aspire or Vcarve pro
Chio, If you know or can calculate the angle of the bevel/draft of that pocket perhaps you could match up a small tapered ball nose to come in there on a simple profile pass and clean them up. They still wouldnt be dead square (would bug me) but everyone is seemingly ok with these faux shaker doors with radius corners.
If you were going to do this old school, you might see if you can find left skew and right skew dog leg chisels, or a wide dog leg chisel that would give you the room to grind a left and right skew on one chisel.
Calculate the grind angles needed so that as the bottom face of the dog leg rides on the bevel of the door, when the angle on the chisel hits the miter point at the bottom of the bevel it also hits the miter point of the top of the bevel.
The left and right skews would meet at the miter points, giving you a clean corner, or at least it would in wood. I'm not so sure about MDF, but you might have success, as it is not a lot of material to remove and it should slice away uniformly, since there is no grain to speak of.
I hope that makes sense the way that I phrased it.
Hope this helps.
Forgot to mention,
If the inside profile is bevelled as I am seeing in your first pic, you just need the Vbit to climb out of the corner at the same angle as the Vbit. This will create the square corner as seen in your fist pic. Im not familiar with your software, but this is very easy to accomplish in v-carve or aspire. Its simply button to click in v-carve.
The problem with the V-bit option (using a Vcarve toolpath) is that the corner will be sharp on the face but still radius in the pocket because the diameter of the tool will not allow the tip of the V bit into the corner at depth. It can give the illusion of a sharp corner because the outer face of the door will have as sharp a corner as the bits tip will allow but it will transition to a radius as large as the V bit or fly cutter left in the first place.
This is dead easy with software. Not really a 3D function.
I use Sheetcam, about $200.00 to run my CNC. 2 spindles, drill block, 12 position tool changer.
If you have a "normal" machine, Les should have a post for it.
It does what you're looking for with any angle V bit.
Thanks for all the responses.
I have spent a lot of time trying to trick the software into climbing out of the corner to create the bevelled corner but have had no luck. Maybe because my version of enroute is "ezynest" it may not have the functionality Marty spoke about?
We cut a job and cleaned up corners by hand. This got us by on one job and shows the great potential of cutting our own doors, but certainly not an efficient procedure moving forward.
My next plan of action is looking into Vcarve which looks like a more cost effective software solution.
Before I do that. I'm still learning Gcode but by rights wouldn't this instruction inevitably turn into Gcode? therefore if i knew the gcode I could write it in?
Not asking for the actual Gcode itself, but if someone said yes it's possible I would look into the gcode side of things before i made the investment.
Thats a bugger Chipbored,
I have attached a few images of my attempt at getting the sharp corner.
I can't find any options relating to open contour on the engrave cut I am using to cut the line I have on a 45 angle in the corner. Even when I select 3d line (which I thought did what I needed) it still just plunges in and cuts that line without ramping in or out.
I have also tried putting a straight line next to it and telling it to come in on a 45 degree angle over the length of the chamfer. It comes in on the 45 angle but not ramping in.
It looks like you have what you need there.
A big thanks to Marty for helping me out on this one. A CNC wizard! worked it out in the end.