CNC Retrofit of Smithy 1324 CNC

Hi Everyone,

I am new to the list. Most of the posts are over my head but I am
beginning to get a general feel for the lingo of CNC.

I would like to give you a little history of my hobby and training
for that hobby.

I have been a computer buff since 1979. I have since owned or had
access to computers and write programs in C, C++, Visual Basic, and
Palm handhelds use C++ and basic. I also write embedded programs in
C and basic. My hobby extended into electronics about 4 years ago
and I have received training from the local community college through
digital circuits. I can program PIC, 68HC11, DSP, and Basic Stamp
devices. I have built one robot using the MIT Handyboard that uses
encoders and ultrasonic distance sensors. All it does is run around
and avoid "most" objects. I understand stepper motor technology and
have built and used several circuits to drive old floppy disk
steppers and many others I have salvaged from fax and old printers.
I have successfully used encoders to govern speed and position using
both stepper and reversable motors.

I bought the Smithy about 4 months ago and have been reading as much
as I can, and can afford, to bring myself up to speed on various
techniques of machining metal, mostly aluminum and plastic, but I
have some ideas about using steel. My main interest initially is in
cutting gears and threads for drive systems.

I have a Vertex dividing head with three dividing plates. It can be
positioned from vertical to horizontal. I have a three-jaw chuck to
fit to the head.

The Smithy company refers me to Flashcut CNC for a retrofit package
for this Smithy. They quote me a three-axis outfit price of $3125
which includes controller and motors. I believe it is with stepper
motors and not servos.

My first question is: What is the best CNC software for a home
hobbyist that can output DXP to the Flashcut system? I have looked
at BobCad, Deskproto, and SurfCam. BobCad has a very attractive
price range and the version 17 can do 3D. I looked at the "G" code
syntax and it looks pretty straight-forward. My initial goal with
CNC would be to set up standard cutting tool-paths for plastic
(Delrin) and aluminum gears for robotic drive gearboxes.

My second question is: What is an affordable CAD program that can
interface with the low end CAM programs above? I haven't looked at
any in this regard.

My money saved for this hobby has almost been depleted. I need some
type of "target" amount based on a hardware and software
configuration selected in the near term for future implementation
(when I can save the monies required).

I have the computing power in my shop to handle any of these packages
already. I have computers that run DOS 6.2, Windows 3.1 and WFW
3.11, Win 95, Win 98, Win Me, Win 2k, and now my wife has a new Win
XP. The processors range from 286 and 386 (both retired but
revivable), Pentium II 233, 350, and 650, and Celeron 400. The
motherboards are mostly Abit with a new Gainward I am trying out.

Any input would be most appreciated and highly valued. I have a
large learning curve but I am diligent and have the desire.

Thanks for your time.

Ted

ted@...