Attempting a Boss retrofit...

Hello all,

I've just gotten my second Bridgeport Boss CNC. The first one I had I
started researching a retrofit but couldn't get any good information
on the actual proceedures so I gave up and sold it.
Now I'm going to try again.

First, let me say that I have a machine shop and all the tools needed
to complete the installation. I also am a used machinery dealer so I
have access to all kinds of mag starters, breakers, transformers and
such. This machine I am doing for myself.
I've never done this before so I am at the very beginnings and could
really use some serious babysitting. I don't understand electronics
that well although I'm ok with electrics and computers.

My goal is to get this Series 1 Boss CNC machine working (this one
has most of the electronics destoyed already). I like the look and
feel of Master5 so I'll give that the first shot as the software.
All the original componants seem ok, but it really appears as though
somebody opened the panel on the power box and kicked the internals
with a hard boot for about a minute. Basically all the plastic wire
holders and bridges are broken so I cannot apply power safely to the
machine as it is. The transformers, reactors, mag starters, etc, all
look fine, but the wiring has ends broken off...etc. Everything on
the CNC side (side panel) is untouched.

Now some questions.....

First, even though I will eventually switch the original amps for
Gecko's or something similar, I would really feel better if I could
figure out how to use the original drives right off. The original
boards are probably ok in this machine although I have no clue how to
hook them up? With something like the Geckodrive, you get some sort
of instructions as to what wires go where but finding the location
that the originals would accept step/direction signals is a total
mystery to me.
The same thing goes with the power supply. The original machine has
what appears to be a large 460/230---> 60/70/80v transformer in it.
It states it is 3 phase and each "leg" seems to be going to what the
BP installation manual refers to as an axis "Reactor". I'm wondering
if this transformer is still useful...aftermarket drives or not?
These "Reactors" look like transformers but I'm guessing they might
be rectifiers for the axis motors (which are DC right?). I should
mention that this machine has the standard Nema 42 steppers.
So, does anyone know enough about the original BP electrics and
drives to assist me in using the original transformer, "reactors",
and motor drives to interface with a PC parallel port? In some ways
I'd rather use at least some of these componants as they are already
mounted and rated for the machine....which leads me to.....

The next step....

I fear that the answer I will likely get is "Tear it all out and
start from scratch with Geckos".... which is ok, and I will if I have
to.
I do wonder though how the performance of the Gecko's 201 is with
these large 42 sized axis motors? As we've seen lately, aftermarket
sofware is getting closer and closer to being true CNC and
less "hobbiest" so I wouldn't like the idea that the machine itself
doesn't have the power that it did umpteen years ago even though the
control software has far exceeded the original Boss. What drives
(aside from the originals) have no performance loss over the
originals? Bridgeport Boss machines are professional machines even
though they are steppers and I don't want to turn it into a toy.
Also, does anyone know how I would use the original power supply with
these aftermarket drives? It's a beefy sucker and I trust that it has
plenty of power for the motors (of course)?

Unfortunately, I am going to need some "find this wire and attach it
to this wire" type of assistance. I don't expect that for free and
will find some way to help out the people who can help me through
this first project. Perhaps because I am in the machinery dealer
circles I could offer to help people find things and transfer them at
my cost or something similar. Regardless, I would be very
appreciative to people who could help me through this.

Please feel free to email me.
audiomaker@...

Many Many Thanks
Sean