4. Bolting the gantry to the frame and aligning the gantry rails.
Needless to say - a lot of problems.
a/ First to say i have dry bolted the gantry before painting all. It was ok. So what was my surprise when everything was painted, the machine fixed on the welding jigs for comfort and the gantry will not fit. So i called a friend that helped me and 3 times i had to lift the gantry and lower it, mean while widening the holes. The reason. This is crazy- the machine is outside, the sun heats the frame and it widens. cause i made the machine in the winter...
So basically now i cover all the time it so it could not heat . My garage is small i mean to work inside.
So at the end i squared perfectly the gantry and bolted it
b/ Now next unsuspected problem. How do i fit the rails on the gantry to be perfectly square with the long rails on the frame? I knew i could do it somehow but in reality it was a big challenge.
I know how to do it if say i make 10 same machines, a fixture and no problem. But how to do it on the cheap. Cause this machine really ate a lot of money spend on little things.
After a lot of thought i fixed the straight edge perpendicular to the base rails and decided to start with the upper rail first.
Once the upper rail was square, there came the problem with the lower rail. A friend of mine says we have all necessary stuff always at hand. So i was in no rush, thought it a whole weekend and just have done it.
Another difficulty was that i do all alone at home with no help, so first i more or less squared it using clamps and then drilled and tapped 2 holes only. Then aligned and bolted until happy. Then drilled the rest of the holes directly on place and bolted. Photos speak better than words how all of this was done.
Of course i managed to chip the paint here and there so it seems when everything is working i have to retouch it at the end. No big deal.
2
equal pieces of aluminum square bar were used to fix more or less the correct distance to the upper rail.
http://www.mycncuk.com/attachment.ph...id=12401&stc=1
Both were precisely squared to the straight edge which was squared to the base rails. 2 pieces of rail were used to support them, a kind of parallels . Not seen on the pictures at the end only one was used at both sides so to make sure the fit is perfect and is really squared.
http://www.mycncuk.com/attachment.ph...id=12402&stc=1
Holes were marked, 6mm drill used to clean the epoxy so it will not unglue or raise during drilling the beam, then 4.2mm drill to make the holes and then tapped. With the help of the nice little block i have.
http://www.mycncuk.com/attachment.ph...id=12403&stc=1
On all drilling and tapping the gantry was clamped so it will not move around. here is the fixture which helped me align the lower gantry rail. Dont laugh at my square, had to clamp a rule to make it longer. I said we have all we need at home, just some imagination is needed.
Used thickness gauge though to align it perfectly /yes i love that word/.
Note should be taken here that when i bolted the 2 plates from the Z i pushed them from behind till they touched the screws, so i know they are alligned to the bearing blockes, as the holes are laser cut. I mean because of this i am sure that their edges are parallel with the corresponding rails. Later i will have some additional opportunity to align them on one plane/the z face plate/ as i can move one of them a bit back.