4' x 4' x 8" Router Build

[Neale]

I know that you've had a look at my write-up already. I used 3mm wall thickness. If I were doing it again, I might have used 4mm for some of the parts (like anything that has a rail bolted you it) just for better damping. However, from a strength point of view I am happy with what I have, remembering that my machine is very much hobby class, not commercial/production. Just recently I have been machining quite a lot of small steel components. I use small (2-4mm three-flute coated carbide designed to run without coolant) cutters at around 7-8K RPM and am getting good results. Again, not production-style heavy cuts but the ability to machine more complex profiles (with some 3D work as well) means that I use the router in preference to my vertical mill. My gantry is quite stiff (three 50x50x3 sections). I'm pretty happy with the overall capability which is much more than I might have expected and way beyond what I had hoped to achieve.

This is just one data point from one user so consider it alongside other opinions and designs but it emphasises that engineering design is as much about compromise as ultimate performance in one aspect. After all, my machine is too slow for an ideal woodworking machine and much too light for decent metal cutting. The fact that I can get acceptable results, even if not optimum, owes more to luck than judgment...