Joe's 1000x600x200 steel and aluminium router started

[devmonkey]

Out of interest did you put a moat across the two rails when you poured it?

Hi Clive, yes there was a moat, I put it outside of the frame at one end. The rails are planar within 10um, I checked them with my laser software. Or at least they were when I fitted them, they have probably drifted a bit as I've hoisted the machine around the shop a couple of times since then. I will recheck them at some point.

I didn't post anything about how I did the pour but there are two important points I'd like to pass on to get the best result,

1. As per Boyan's findings the moat should be outside the frame, close to the same cross section as the rail support epoxy and the pour should extend beyond both ends.
2. You must use non-absorbent material for the moat and dams, anything else and non-linear capillary action into the material will mess things up. I used 10mm pvc angle for the dams and pvc trunking for the moat. The dams were stuck to the frame with thin toffee tape which worked well (didn't leak) but was a pain to get off.