Make: Projects

Magnetic Chip Shield

In under an hour, build a small shield to shelter you from flying chips.

Steps

Step #1: Clean up the aluminum

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  • Take the rough bar, and trim it to 4" x 5/8" x 1/2".
  • Dimensions aren't very critical in this project; if you have a 5/8" x 1/2" bar, just take a very light cut off each side to make it look nice.

Step #2: Mill a groove

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  • Mill a 0.25" wide groove 0.25" deep. It should be in 0.10" from one edge.
  • I'm using one of these chip shields in the second photo. Notice the pile of chips behind it and lack of chips in front.

Step #3: Drill the set screw holes.

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  • Cutting the groove in the last step created a thin side and a thick side. These holes will be drilled through the thick side.
  • Spot, drill, and tap three holes 0.125" from the top, at 1", 2", and 3" in from one end.

Step #4: Attach magnets

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Magnetic Chip Shield
  • Drill two holes on the bottom with a drill bit the same diameter as the magnets. Don't drill all the way through, just deep enough for the magnets to sit flush.
  • Glue in the magnets with J-B Weld or another suitable glue. Make sure they are perfectly flush with the bottom of the part.

Step #5: Cut and insert plexiglass

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  • Cut a piece of 0.25" thick plexiglass. Make it whatever dimensions best fit your machines. 4" x 3" is a convenient size for me.
  • Slide it into the slot, and insert three 6-32 setscrews into the holes you drilled and tapped. Stick it to your machine and enjoy!
  • This cannot replace safety glasses, nor is it meant to. It just helps reduce the amount of swarf flying at you.