Newbie follow up

Several months ago I posted my first message regarding a future conversion
of a series I / II to PC control. Well as luch would have it, I just picked
up a used series I, with a long gone Boss controller for a steal. Machine
has been sitting for a good 2-3 years as it became to expensive to fix and
too much trouble to haul out. Following an afternood of tugging, pushing
and general cursing, it now rests in my shop.

The spindle wiring I can handle, along with the phase conversion etc, but it
is the PC to stepper I'm going to need help on. Here is my dilemna:

In case your wondering, My use of this machine will be strictly personal
hobby projects, not a production line setting. I'm not after the fastest
machine speeds or the quickest part production, and am more than willing to
wait the extra few minutes for parts.

So here goes:

First the software questions:

From what I have read over the last few months EMC is the way to go for low
cost CNC conversions. I'm open to this, but let me throw in a few
hiccups....

I have several high end software packages available at work, including IDEAS
and Solidworks (and possible an old version of Pro E) . I'm more than
skilled in the CAD side of things, but we have never compiled anything to be
run on CNC. All our work stops on the modeling side of things, and is
passed off to the next person in the chain. Are these packages a better
solution to EMC for a user in my position? Do they do what I'm after or is
there an "middle man" program that goes from a IDEAS file to G-code? (for
exmaple) I'm ready to pull the manuals off the shelf, but rather save myself
the research if I'm barking up the wrong tree. If my current CAD
applications are just "too good" (i.e. too complicated) for my pursuits, any
suggestions on hobby CAD programs? How about the conversion from CAD file
to a ready to run G-code file?


Moving onto the Hardware side of the equation:

-Again, its a low use series I with stepper motors. Its the control
that died (from what I'm told) and the steppers should be fine. What
exactly "the control is dead" means is beyond me, so I'm unsure what can be
salvaged. I'm inclined to start anew, as opposed to trying to keep a dying
beast alive anyway. Without starting a huge flame war, what is the
reccomended approach to interfacing what I have to PC. I've seen some
glowing reviews of the Gecko drives a while back. Is this a modern approach
which will work well? Posting seem to indicate this is also an inexpensive
route to take. Additionally, I'm assuming I'm going to need some sort of
power supplies for the motors. Are these the type of things someone handy
with a soldering iron (but far from an EE) can handle, or is there a
reasonable cost alternative? For that matter, what would a "reasonable
cost" alternative cost? Anyone document a conversion like this relativly
well? (even better, anyone document it online?) I've read most of the
links, but most setups go from before to after in just a few pictures.
Frankly, I'm still too low on the learning curve.

Finally, any suggested reading on the CAM side of things. I've never
even seen a line of g-code and have virtually no experience on selecting
toolpaths, plunge rates etc. Ran a part or two back in college (i'm a Mech
Engr) but that was a few years back and there was a TA who held by hand
along the way. Regular machining practices I'm OK with, as I've been turing
handwheels for some time, it is the CAM oriented side than is blank right
now.

Sorry about getting so long winded. I'm sure I will plague you guys with
more than a few questions in the coming weeks. If you prefer, I'll gladly
take this off list if it is too off topic.



Thanks in advance,

Vincent





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