Machine rebuild time - options...

**CraftyGeek** · 18-10-2011

Thanks for the response so far.

Over the last few years i've done loads of research into mdf based machines...it was only 18 months ago that I finally had space to build one after collecting electronics etc over a period of years.
So i've had a learning curve already - ultimately I can see that mdf is going to limit me (as well as annoy).

Right now, after having a quick look into material costs a bit more closely, I don't think I can go for a new full ally profile build as I simply don't have the funds. From a quick glance - ally box & steel box don't actually seem to work out that much cheaper.

My current thinking now is to start upgrading my existing machine into more of a hybrid - then keep upgrading as & when I can.

The biggest problem I have at the moment is the main table/base - it just isn't up to the job. So i'm thinking about making some sort of metal frame for the table - then attaching the rest of my current setup to that.

Tool wise I have most hand held power tools (inc angle grinder & jigsaw) with a circular saw mounted as a table saw & also a router table....no pillar drill. I plan on getting a better table saw & also a chop saw at some stage soonish as well.
I have very little experience working with steel...i've done much more with aluminium & would be more confident working with it as a result.

As welding isn't an option - how would you suggest creating an accurate solid frame out of box stock?
I have a metal supplier near me that could in theory cut pieces to length for me - but how best to join them?

**JAZZCNC** · 18-10-2011

Originally Posted by CraftyGeek

Right now, after having a quick look into material costs a bit more closely, I don't think I can go for a new full ally profile build as I simply don't have the funds. From a quick glance - ally box & steel box don't actually seem to work out that much cheaper.

Box section steel is half the price of Ali box section, I pay around £20 for 7.5mtr 50x50x3

Originally Posted by CraftyGeek

As welding isn't an option - how would you suggest creating an accurate solid frame out of box stock?
I have a metal supplier near me that could in theory cut pieces to length for me - but how best to join them?

Using plates Drilled and bolted to the frame.! . . . Thats why a decent pillow drill is so usefull, almost essential if you want an easy life.

**m_c** · 18-10-2011

Originally Posted by JAZZCNC

Box section steel is half the price of Ali box section, I pay around £20 for 7.5mtr 50x50x3

You'd be surprised. I know when I priced a project earlier this year, there wasn't that much difference in price for the box section that I needed. It was all the brackets that bumped the price up. I still went for the alloy though, as it was lighter with less flex which suited the application, and the company cut it all to length so all I had to do was bolt it together, which saved me a lot of time.

**JAZZCNC** · 18-10-2011

Originally Posted by m_c

You'd be surprised.

No I wouldn't 50x50x3 Ali is £35 plus vat + Del (Ali warehouse) for 5mtr and as of 2 weeks ago when I last bought some 50x50x3 steel box section was £21 for 7.5mtr. Inc Vat.! (Delivered thou it's only next village so don't count really. .Lol)

**Jonathan** · 18-10-2011

Originally Posted by m_c

That's ok if you have the equipment to deal with full lengths

Equipment = hacksaw (takes a while but it works), or get the supplier to cut it. The place I got mine from cut it without charging, and also gave me a load of free bits :). I worked it out so that each piece would fit in the car, then did the rest of the cutting myself to make sure it was accurate. If I recall correctly the 60x60x3 steel box section I got was £25 for 7.5m.

Sell the spare on eBay, it goes for lots there!

Originally Posted by m_c

If you don't have a pillar drill, scribe, centre punch etc. then

Then get one ... you're not going to get very far in life without a pillar drill. Well... I wouldn't! Surely you would need both for aluminium or steel.

Originally Posted by JAZZCNC

No I wouldn't 50x50x3 Ali is £35 plus vat + Del (Ali warehouse) for 5mtr and as of 2 weeks ago when I last bought some 50x50x3 steel box section was £21 for 7.5mtr. Inc Vat.! (Delivered thou it's only next village so don't count really. .Lol)

Also to get the same strength in Ali you'd need more than 3mm thick...so comparing like with like would make the difference in price even greater. Also I think Tom was comparing aluminium profile to steel box, and profile is a lot more expensive than box (though also significantly stronger for the same outside dimensions).

Two weeks ago... does this mean you've started the next machine?

**JAZZCNC** · 19-10-2011

Originally Posted by Jonathan

Two weeks ago... does this mean you've started the next machine?

Nope that beast will be 100x100 filled with sand and built like a brick shit house.!! . . . Was for steel door at work to stop thiefing bastards.!!

One other great tool and cheap thats quick for cutting steel is 1mm micro cutting disc's in angle grinder, go thru like hot knife in butter, they also easily go thru hardened rails and Pad locks.!