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Tech index -> Custom Work -> Shocker SFT eye covers

These are new parts required for my beam-beak eye milling (which as its own page here). After a Shocker body is milled and prepared for the eye install, a new left-side eye cover is necessary to cover the components. For simplicity I prefer to mirror the Shocker body the same as the stock Vision side, and create a new eye cover similar to the stock ones. These new eye covers are slightly altered to make it a little easier to install wired eyes, but they're mostly the same.

The milling program is such that the part's features (notches, holes, etc) are milled into the material block first. Once all those features are complete, a cutter follows the outside shade of the eye cover, which then falls out from the material. This cutting method produces some leftover metal present when the parts break free, so some small post-machining cleanup work is required (below).

To remove the leftover material, I use a vertical belt sander to hand-grind the covers to their final shape. The factory eye covers are milled in a similar way to this, except they're re-inserted into the CNC for a secondary program which removes the leftover material automatically. I don't do this since I find it to be unnecessarially time-consuming compared to using a sander. (it's not "PRECISION"....but it doesn't have to be).

Once my eye covers are ground to their final shape, they must be deburred to remove the metal shavings left on their edges. I also choose to do this by hand (usually). Once deburred, the eye cover can be used, though often I will choose to perform additional operations such as media-blasting or polishing. Below are a few pictures of the various finished products.

I usually choose to leave the parts raw since they're so small and barely noticeable, but if people desire I can blast or polish them. The blasting process is often called "sand blasting" although it's not actually sand but rather a silica medium, which produces a rough but consistent finish on all surfaces. The polished covers are buffed using white rouge and a buffing wheel until they show a mirror finish.
Parts can be anodized in any of these forms. Blasted parts will have a matte anodizing finish whereas the buffed/polished parts would have a glossy finish. Blasted parts are more resistant to oxidation so that's a much cheaper alternative to anodizing that I like to use (although they can still be easily scratched). Raw parts will tarnish over time but since the eye cover is so small it's barely noticeable. If tarnished they can be re-buffed to return them to their original look.

The finished Shocker looks like this: (glossy eye cover shown)

Machining Program:
My current eye cover machining program can be found here. Instructions for machine setup are below...
- Material stock: Aluminum 6061 sheet, 1/4" thickness. Length is at least 3.25"; width is at least 1.6". (this will cut two covers)
- The mill needs to be equipped with the following features: multi-quadrant circular interp; cutter diameter compensation (G40/G41/G42). This program was written for a Fanuc control.
- Set two work offsets: G54 in the workpiece's upper-left corner; G55 in the upper-right corner. Suggested to simply use the two ends of the vice for simplicity.
1st setup is the backside features, using G54.
2nd setup is the frontside features, using G55.
- Z-zero is 1/2" above the part. All tools are programmed to their tips.
- Tool1 is a 1/2"dia edgefinder (or 1/2"dia metal pin) which will be used during the progam. Set a tool length offset for the tip of the edgefinder as if it were a regular tool.
- CDC is not programmed for the detent hole and counterbore operation. As a result, if you need to adjust the hole dimensions, you will need to physically alter the program (line N655 and N665, then repeated at line N695 and N705).
- CDC is available for the final eye cover shape, but you will be unable to adjust this before dropping the cover slug from the material. As a result, be prepared that your first part may not be sized correctly. Measure it then make adjustments and resume the program for the second part.
- DO NOT BEGIN THE PROGRAM WITH MATERIAL IN THE VICE. A hard-stop will be used to insert material.

Tool offset:	Tool setup:	CDC:
T1	1/2"dia edgefinder or similar
T2	Centerdrill #3
T3	Drill 1/4"dia, HSS
T4	Endmill 1/4"dia, HSS 2-flute	0.25
T5	Endmill 1/8"dia, HSS 2-flute	0.0
T6	Ball endmill 1/4"dia, HSS 2-flute	0.0

Note: do not substitute the T4 endmill for another size.

Program progression:
1. Index hard-stop using the 1/2"dia edgefinder
*M00, insert material stock against the hard-stop
2. Backside material removal cycles
3. Eye lens notch cycles
*M00, remove workpiece from vice
4. Index hard-stop using the 1/2"dia edgefinder
*M00, insert material stock against the hard-stop
5. Centerdrill, drill holes
6. Bore detent hole and counterbore (G13 pocket cycles)
7. Inclined surface routine
8. Ditch mill profile, finished cover will drop from the material stock.

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Tech index -> Custom Work -> Shocker SFT eye covers