Summary

I created a bracket to hold my DeWalt DW660 spindle on my ShapeOko 2. This bracket conforms pretty well to the non-round shape of the DW660. I wanted the bracket to be pretty stiff and strong, so I designed it to be hollow and then filled with liquid epoxy. I use West System's Epoxy. The walls are all about 1.5mm thick and there is some internal structure.

The top bracket has a mounting plate for a limit switch. I used McMaster 7779K22

Instructions

I printed on Replicator 2 with ReplicatorG software. Settings were:

Infill 100% (this fills the 1.5mm walls 100%, not the whole model
Shells 0 (if you make >0 there is a bug in skeinforge where it will not fill in the 1.5mm wall all the way)
Layer height: 0.2mm

I created the STL files by using the Export STL plug-in for SketchUp. Then I ran them through Netfabb's STL fixer.

The SketchUp file has a Mouse Ears layer which I like to use to help hold the part flat to the build plate.

After the brackets are printed, fill them with liquid epoxy. I used West System's epoxy. It's about as thick a maple syrup, and I just poured it inside. I noticed that the model leaked a little on the face where the two brackets mate. To prevent this I just added a little epoxy at first and let that dry so it would seal that face, then filled it up bracket.

The brackets are held together by M5 x 90 bolts. The hex nut for the bolt slips inside a hex shaped counterbore and is held in place with the hex nut retainers.

The brackets are bolted to the ShapeOko with M5 x 25 socket head cap screws. I do use washers under the head side; the washers are a tight fit in the counterbore, but they do fit.

ShapeOko 2 DW660 Bracket