Thread: Rockcliff Router Build, MDF
So the sun was out, Jackie (wife) and Hanna (daughter) went shopping and I was left to get on with the build. Sweet!
Right Iíve got a few ideas on things Iím going to change with the default rockcliff plans, you donít have to do what Iím about to show you, but you may as well as it will make for a better machine in the end. (I think)
Iíve decided to add skate bearings to my threaded rod to support them, as I say the plans donít suggest to do this but when your machine is doing rapid movements you can get whatís called "whip" in the threaded rod if itís not supported. At first I was only going to support my threaded rod at the opposite end to the motor, but then I thought well why not do it both ends. It will only make it better anyway, so thatís what I did.
You can see Iíve cut out a 22mm diameter whole to receive the skate bearing, the skate bearings are 8mm inside diameter by 22mm outside diameter and they are 7mm deep. Iíve bored 10mm so the bearings sit 3mm from the surface. Before I did this I drilled all the way through with a 14mm bit so the threaded rod and nut can pass through and spin, that would be the smaller hole you can see in the pic viewing from the leadscrew side.
Iíve also drill out two 14mm holes for the rails to pass through.
Last edited by Lee Roberts; 20-08-2010 at 12:11 AM..Me
So the sun was still blazing and the girls still shopping, so I pushed on and got some more done.
I decided before I went on to the next stage, I would test fit the rods and rails and the bearings of course, you'll notice that Iíve put my bearings on the outside of the machine. This isnít a must but I would like to put some tension on the rods so by putting them on the outside we can do just that.
To test fit the rails I had to make the 50mm x 50mm rail support plates, again I just marked the centre and drilled out a 13mm diameter hole to receive the rails. You can see the rails are to long so ill cut them down later on in the build, I may not though as I could just rebuild the machine to a bigger size !
Last edited by Lee Roberts; 20-08-2010 at 12:11 AM..Me
Guess what? Yuup! The suns still out and the girls are still shopping!
Ok so everything looks good to go, there is a couple of things Iíve noticed at this point so ill talk about them now.
The 14mm holes I cut in the rod support plates are small; the rail supports allow me to move the rails in all directions so as to get everything square, parallel and lined up correctly. There is enough space with the 14mm holes but I think given the choice I would have preferred 16mm holes so there was just that bit more room and clearance for the rails so I may re drill these holes at a later stage, though there isnít really a need.
The other thing Iíve discovered though it was expected is that I will need to rout out some of the table on the underneath where my transmission nut will be fitted, again Iíve deviated from the plans and Iím going to be using a different type of transmission nut to the wing nut in the plans.
What my plan is, is to mount the transmission nut in the middle of a piece of MDF under the table, ill post some picks of this so itís more clear what Iím talking about later on in the build log.
Ok so Iíve cut my routs to receive the oilite bronze bearings, I went to every shop in Wigan trying to find a 5/8" - 15.85mm round end router bit. Could I get one?
Yep for £63.27, so no that didnít happen, instead I went for the bit I already had and that was a 5/8" flat bit.
You can see in the picks that Iíve test fitted the bronze bearings and mounted the table onto the rails, I also started with the Bronze Bearing support plates that go underneath to secure them, again the plans call for 50mm x 50mm blocks but Iíve made mine 50mm x 330mm so they are one piece and very accurate. Iíve got one cut and routed and the other is done and just needs cutting from the sheet of MDF Iím working from, I will post about them tomorrow once they are ready to be used and fitted to the table.
Itís now 01:55am and my eyes need a rest so ill say good night.
Last edited by Lee Roberts; 20-08-2010 at 12:31 AM..Me
Yep you guessed it! The girls went shopping and I had time to work on my build.
Ok so today I managed to work on my transmission nut system and finished cutting the bearing support plates or whatever you want to call them. I will be using some small nuts and bolts to fix these in place along their full length, ill post on them later in the week.
I also started making some beta transmission nut holders as well, after I made them I test fitted everything to see how it all looked, I needed to make a rout out for the holders to sit in so the transmission nut sits in line with the rod and bearings. I need to rework this as the transmission nuts are still to low by about 3mm.
Last edited by Lee Roberts; 20-08-2010 at 12:35 AM..Me
After that I reworked the transmission nut holders only this time I made my very first ever jig to get them spot on with a router, rather than the bench dill as I found the drill wasn’t doing a good enough job with accuracy and so on. (or was that just me?)
Try not to LOL till you pee yourself, it’s my first ever jig don’t forget! And besides that it does the job. I managed to get some new further beta holders made; by then it was time for dinner and time for "family time" so I had to stop.
So my setup is hand tools and I couldn’t really do a good job at getting the drive nuts spot on. I’ve now moved onto making delrin drive nuts as the ones I made above are just no good really.
Last edited by Lee Roberts; 20-08-2010 at 12:46 AM..Me
Great build Lee and am following this very eagerly. How do you find the bronze bearings to be with the ground rails are they smooth ?? I am at the moment finalising my list of components and am torn between the Pacific ceramic bearings or these bronze bearings any advice would be greatly appreciated CHEERS! :D
Hiya, been a busy guy these last few days not had a chance to work on the build.
I would say they are ok, I’m building with 1/2" size rods and they seem to be fine for what I’m going to do. Pen5 has the 16mm rods and is more than happy with them; my father in-law said that they are great until they wear down (bronze bearings). I can’t see they will with the light cutting I’m going to be doing, but I guess it’s fair to say they will at some point.
Only thing I found that I can say I noticed about the bronze bearings was, I put them upright on an off cut of MDF and the impregnated oil started to soak into the MDF a little. Also if you can, try and keep everything clean as dust seems to get in between the rods and the bearings. I know that’s probably obvious but I didn’t think about it when I was test fitting everything and I noticed small scratches on the rods, nothing major but still not what we want.
Can’t really think of anything at this point mate sorry, I’ve got to points of contact for suppliers if you need a price or anything like that.
Last edited by Lee Roberts; 20-08-2010 at 12:49 AM..Me
Some time has passed and Iíve not been detailing as much of my build log as I should have, anyway it is now starting to look like a machine:
Last edited by Lee Roberts; 20-08-2010 at 01:38 AM..Me
So i started looking at how i was going to mount my motors and this is what i did:
So i used some Stainless Steel Tube, and some M5 Threaded rod, now i just needed some ali plates.
So i did some testing as i'v never worked with ali befor:
Ok i can see what its going to be like so lets crack on and see what we can come up with:
above i used some Center Drills to try and get my holes as good as i could, its taken a few gos at getting these right but after i printed some markings to work for on stick backed papper it was that bit easyer!
I managed to get all 4 holes done and also counter sunk them ready to recive the ss tubes above:
Last edited by Lee Roberts; 24-09-2008 at 05:18 AM..Me
Then it was just a case of cleaning it all up with hand files and drum sanders:
and mounted to a motor:
i used a whole saw cutter on the bench drill to to the big hole for the motor face plate, not an easy job on a cheap drill but i got there in the end! only 2 more to do !
Last edited by Lee Roberts; 24-09-2008 at 05:33 AM..Me
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