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I agree with the folks saying maybe go for a milling machine. You could get a little bench mill like the smaller Precision Matthews for not too much more, but tooling and everything will be another half to 3/4 of that budget for mills. Great if you want to get in to milling, though.

For nice new drill presses, Jet and Powermatic both offer solid machines, especially variable speed ones. Make sure you get yourself a good drill press vice and actually use it and clamp it down. And a set of really good metalworking drills, like these or a Norseman set or something. Those two things will make just about any drill press you wind up with more than capable.

It's interesting that those diagrams don't show the Saftronics VFD. I wonder if that was added later. If there are no other diagrams or manuals for the VFD, you'll need to trace every single wire that is connected to the VFD and write down where they go.

You can order the plug and go kit if you are ready, but I would think carefully where and how you want to physically mount the 7i77 ('i' not '1'). Where the current distribution board board is is a logical choice, but you'll want to think about if you have enough room there below the VFD to be able to get to the connectors to connect all the necessary wires. Also, for what it's worth, the difference between the 5i25 and 6i25 is that the 5 is PCI and the 6 is PCI-E. You'll have to decide if the extra cost of the 6 is worth not having to worry about finding a PC with PCI slots in the future if the PC dies.

While you are ordering stuff, I suggest also ordering three of these (or similar): https://www.amazon.com/gp/product/B017M4QWEY

These will let you make short adapter/extension cables to connect the existing DB9 terminated encoder cables to the 7i77.

Rivnuts, Astro Pneumatic Tool 1442 Nut/Thread Setting Hand Riveter Kit, 13-Inch https://www.amazon.com/dp/B003TODXQW/ref=cm_sw_r_cp_apa_5ZXYzb1S8Z4Y7

Found a sampler pack on Amazon of Gauges 26-20, going to experiment with those to get a sense.

Am I nearing a minimum thickness required for stamping?

Thanks! I'm struggling a little figuring out exactly what you're referring to on google, though -- are we talking about a "multi-finishing wheel"? Or something else? I can't seem to find anything in green...

If you go for the DIY belt sander, have a look at these belts:

https://www.amazon.com/dp/B008S3CY1E/ref=psdc_552586_t3_B00SUMTD8U

I worked at a commercial kitchen hood manufacturing company and we used a product very similar to this to put the grain back into what we would grind on.


Walter 07J446 COOLCUT Linear Finishing Flap Abrasive Drum - 60 Grit, 4-1/4 in. Surface Finishing Drum. Finishing Products and Accessories https://www.amazon.com/dp/B003O9J5Z0/ref=cm_sw_r_cp_api_i_i7HYCbRJPA62Y

https://www.amazon.com/3M-08293-Scotch-Brite-General-Scouring/dp/B00C0OH5E8