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The issue with horsepower on the spindle and the overall speed is that some of these old routers didn't go that fast particularly if they used stepper motors which loose position if they are pushed. Particularly if you add too large of a spindle and it's weight, not to mention that too much...

More than the HP or the money, the spindle (and cheap chinese spindles are included) will be SO MUCH QUIETER! Like barely hear it when not cutting quieter. It's harder to install compared to a new router. You need an inverter (and ideally 220v power), a new mounting plate, and need to run the...

Or, if the letters are CNC cut along with the holes you might dial in a size to allow machine screws to act as a self tap.

"Mach3" in the specs, syntec control in the pictures. Amateur.

I continue to think this is just a problem of crap sheet (maybe due to PVC supply issues), not a cutting issue per se. Grab a scrap of old pvc and cut that and see?

Some PVC is just like that, I have certainly seen that edge before but not often. I think it's a manufacturing error in how the skin is formed. But, in general a downcut bit or a knife cut first, as recommended above, should work, upcut bit for the bottom edge ideally. Sandpaper block might...

He's also (thankfully) just starting a "summary" series as watching the other 100+hours of content is a little dry.

See novakon.net for a decent reseller and look at those machine's parts versus the sub 1000 machines on eBay. You can buy yourself but the safer bet is the reseller route. Chinese lasers are fine for cutting and OK, but not competitive, for engraving. Check out laser resale too, might get a...

no, and I gather E-cut does do that. But lead in and lead out cuts, finish pass cuts, multiple depth cuts, etc, etc are easily done in vcarve. OP didn't mention the returns.

Neat idea, might be worth playing around with a little at some time but I can see how you might need to be careful on the direction. I would guess cutting vinyl it would be less of an issue but a shallow "drag" to orient it before going deeper into the coroplast would probably be the way to use...

Cut 2D (cheaper version of Vcarve) will work for any channel letter needs, half drills for studs, offsets for backs, etc. Having seen e-cut but not used it, I'd probably still use vcarve / cut 2d esp. if you are starting out as it's (probably) easier to get help with getting it to talk nice to...

Nothing to learn, I don't have a drag knife!

I've noticed that their websites are a little more open about that now versus a few years back. They note sign shops should contact Gemini directly. Sent from my Nokia 3.4 using Tapatalk

10mm is easy. But a compression bit, as recommended just above, is the same as the upcut / downcut you mention. I used a 1/8 compression bit with 4mm with vinyl mounted and it worked pretty well on a few hundred "wing" pieces.

You are correct that the hold down issues are minimal. I was just saying that can lead to a different approach on the laser versus router, and perhaps not a better approach. Greg Sent from my Nokia 3.4 using Tapatalk

Just as a guess, I'd probably do it 1) setup, 2) per letter or 2b) a bit of per letter and sqft. Alternatively setup and a per letter cost with a price / size of letter chart. Do some samples of various styles, time yourself in ideal situation and charge ideal rates based on that. If you get...

I understand all that, but I have described what they told me. I also don't think it's unreasonable to refuse to sell to your competition, so it never was a point I argued about. I'm not a sign shop so it was not a big deal. If I was a sign shop then I would have tried harder. Since now I'm...

Well, beats me and I certainly haven't tried recently. We were told at the time we were competitors and so no account. And, I haven't really cared much for the 15 years after that. Bear in mind that unlike the many sign shops with a CNC I'm an acrylic shop that just does letters on the side for...

This might be better answered in the premium side, but I am starting here as my other post on this subject there has about 7 views and I think 4 of them were me! I'm considering getting (my business) into more serious dimensional letter work to the trade. Either buying an existing supplier...

That's how I handle router jobs and I suppose I could do that more with the laser (I would just line up the holes however unless it was a lot of pieces), but the lack of hold down leads me not to most of the time. The scale issues would remain on this particular job as the tolerances were so tight.