[ATM] A question of diameter and thickness

["Russell Jocoy" <russjocoy@hotmail.com>]

  Hello all on the list,

      Let me start by saying that I have been working for 3 months on a disk
cutting machine to create mirror blanks. I have gathered much information
from my comrade James Lerch, as many have seen his ROBO Disk cutter on the
web. Well my cutter uses no computers and has to be tended by an experienced
experimentor. I am not putting down James"s contraption, but my contraption
actually worked in the same type process,  and worked, with a little 
attention.
       I will not at this time describe the turntable and it's parts since
it would go on and on, but roller blade wheels are involved for the run
support, not bee bee's. I figured that multiple cuts and wear and tear from
glass particles and water would need a roller system that would last a 
while.
Since these wheels roll across asphalt, I thought a spiral at 20rpm's would
not put a dent in these bearings.
      Well let me explain the basic cutting idea.. As said before I have a
turntable at 20rpm's.   The cutting disk is a 4" angle grinder mounted on a
"tone arm" with a diamond wheel cutter. Basically a heavy duty record 
player,
with one twist.(which James's design had built in) The tone arm MUST be able
to move to the size of the disk square to the cut, otherwise you will be 
cutting
a deep angle sideways against the grain. As it stands even square to the 
rotation
you are cutting out a 1/2" groove in a 10" diameter disk, this is because 
the
blade is square and 4" in diameter. (if your needle in your old stereo was 
4"
wide you would have never heard the Beach Boys, maybe thats a blessing)
     If you cut a 3" disk with a rotary cutting machine you will be cutting
maybe 1-1/2" gap of glass unless you "stopsign cut" the glass. The larger 
the
disk cut ,the smaller the glass that needs to be cut.

       Well, now that I have bored all with technical crap,(go ahead and 
laugh
James) I was sucessfull in cutting 2 - 10.375" disks with my contraption.
  The edge was a little ragged, but no more than 1/8". I patted myself on 
the
back and the wind picked up, and my priorities changed real quick.
        I put my shutters up, got out of town, came back to find my home was
still there, cleaned up for two days, waited 12 days to get my power back,
cleaned up some more ..Thanks to Hurricane Frances, Then scurried to find 
out
whether Hurricane Ivan was to give us a double whammy....
        I am back and intact...  a question for the experienced pushers 
(glass
that is) I am about to cut many circles in 7/8" Pyrex and 3/4" plate 
glass.,,
  I remember Jerry Hillman fighting with a 16" plate glass disk for 
2YEARS!!!
I don't want to cut disks that are impossible to deal with for ATM'ers.
  I would love to have suggestions on maximum diameters for the people who
want a nice, no, good mirror , for this thin glass, and only the experienced
can give this advice... Jerry gets a big discount on some Pyrex from me...
    sorry I have rambled on, After 12 days with no electrical power your
priorities seem to get in line...
                            I love this list,   RUSS JOCOY

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