> I got inspiration from these two sites

I ran a quick-and-dirty test on the repeatability of my ugly 
tool length probe switch and discovered that it works 
surprisingly well:

http://softsolder.wordpress.com/2010/04/17/ugliest-tool-
length-probe-switch-repeatability/

Shorter link: http://wp.me/poZKh-15y

A somewhat less hideous version of the probe subroutines 
lies buried in the G-Code accompanying this post:

http://softsolder.wordpress.com/2010/06/15/water-bottle-
spring-cap-repair/

Shorter link: http://wp.me/poZKh-1cI

The trick is to put the G30.1 location far enough above the 
switch to accommodate the longest tool you'll use for that 
job. That's a gotcha I discovered on PCBs requiring both 
carbide drills in a 1/8" collet and twist drills in a Jacobs 
chuck.

I recently got a sack of assorted SMD switches that (seem 
to) have more overtravel, but I'll procrastinate until I 
wreck the ugly one and must replace it.

All in all, a tool length probe station isn't hard to build, 
at least if you're not writing up the project for Digital 
Machinist... [grin]

-- 
Ed

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