1. #1
    Sven's Avatar
    Lives in a, Netherlands. Last Activity: 3 Days Ago Has been a member for 3-4 years. Has a total post count of 45. Received thanks 4 times, giving thanks to others 0 times.
    I am almost ready to connect everything up on my router that I started in September.

    I'll put up some pics of the build later but here is the current state that more or less only needs to connect the bed to the frame and put in all the wiring:

    Click image for larger version. 

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    1250x1250x245 mm
    Last edited by Sven; 20-01-2017 at 06:42 AM.

  2. #2
    Quote Originally Posted by Sven View Post
    I am almost ready to connect everything up on my router that I started in September.

    I'll put up some pics of the build later but here is the current state that more or less only needs to connect the bed to the frame and put in all the wiring:

    Click image for larger version. 

Name:	2016-12-30 14.45.56.jpg 
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ID:	20409

    1250x1250x245 mm
    Looking forward to see more.

  3. #3
    Nice one, looks like a beast.
    What materials is it made of?
    /madman

  4. #4
    ,

    Enviado desde mi ASUS_Z00AD mediante Tapatalk

  5. #5
    Sven's Avatar
    Lives in a, Netherlands. Last Activity: 3 Days Ago Has been a member for 3-4 years. Has a total post count of 45. Received thanks 4 times, giving thanks to others 0 times.
    This is my second router, to replace a 950x550x240 self made.
    There were some design and construction issues in the first one I wanted to get rid of, but that would take a serious amount of work and quite a lot of time.

    As I can not be without a router for long since I use it to make parts for my business, I thought I'd better make a new one, which then would be bigger.

    The lay out from this new one was handed to me by a gentleman who builds machines for a living and for his business he built his own 2500x600x350 router that he uses for high alloy steel if needed.

    He did not approve of my plans to build a epoxy concrete gantry and then offered me his help in designing and if need building mine.

    In the end I copied his layout but used tooling plate instead of steel.
    I bought some tooling plate and box section aluminium from a scrap merchant and bought new tooling plate if I could not find a bargain.
    All copper and ball bearing was bought through ebay and the PC is scratch build for linuxcnc.

    I'll start with the pics in the next post.

  6. #6
    Sven's Avatar
    Lives in a, Netherlands. Last Activity: 3 Days Ago Has been a member for 3-4 years. Has a total post count of 45. Received thanks 4 times, giving thanks to others 0 times.
    Click image for larger version. 

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    Start of the frame assembly

    Click image for larger version. 

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    Click image for larger version. 

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    Arrival of the new tooling plate

    Click image for larger version. 

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    Not the easiest of jobs, getting 175 kilo slab of aluminium up a 10 degree ramp

    Click image for larger version. 

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    The first bonding session for the gantry beam, using bog standard epoxy with cotton fibers

    Click image for larger version. 

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    First time I made a cut on the table saw. It is to use ...

    Click image for larger version. 

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    ... for the plates that become part of the legs.
    Last edited by Sven; 22-01-2017 at 04:37 PM.

  7. #7
    Sven's Avatar
    Lives in a, Netherlands. Last Activity: 3 Days Ago Has been a member for 3-4 years. Has a total post count of 45. Received thanks 4 times, giving thanks to others 0 times.
    Click image for larger version. 

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    The legs have been bonded/bolted.

    Click image for larger version. 

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    The frame horizontals are milled to their size on the router that is the template for mine

    Click image for larger version. 

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    Frame is ready.
    The legs are 100x100x5 mm, the horizontals are 20x150

    Click image for larger version. 

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    With the bed on top of the frame, it is time to bond all gantry beams together.
    In hindsight it would have been better to bond the 6 box sections first and then bond the tooling plate to the box sections in the second session.

    This way might not require milling the gantry flat for the rails, if the bed can be set up very flat.

    Click image for larger version. 

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    First rail mounted

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    Gantry being milled. We ended up at about 0.02 mm flatness over 1450 mm

    Click image for larger version. 

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    As we needed to mill more of the gantry beam than anticipated I needed a new surface to mount the bearings for the Y-axis ball screw to...

    Click image for larger version. 

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    Squeezed in epoxy/quartz flour mix

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    Very happy with the result...

    Click image for larger version. 

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    ... Flat to 0.01 mm
    Last edited by Sven; 22-01-2017 at 04:53 PM.

  8. #8
    Quote Originally Posted by Sven View Post
    Squeezed in epoxy/quartz flour mix
    Why Quartz flour.? . . . That's new one on me.!

  9. #9
    Sven's Avatar
    Lives in a, Netherlands. Last Activity: 3 Days Ago Has been a member for 3-4 years. Has a total post count of 45. Received thanks 4 times, giving thanks to others 0 times.


    After a lot of hassle because of a defective power supply PCB, I finally got some movement today.

    @Jazz:
    Quartz flour because it gives a nice and compact mass, resistance to pressure, with good filling of the smallest of voids. And it is still sort of drillable.

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