Well here goes... Aluminium frame router design

**Boyan Silyavski** · 24-08-2015

I would use no diagonals at all as the structure seems right to me. However i will use 10mm thick plate for the bolt on connections. That should do it

**CharlieRam** · 24-08-2015

Thanks for the quick replies guys.

Originally Posted by Boyan Silyavski

I would use no diagonals at all as the structure seems right to me. However i will use 10mm thick plate for the bolt on connections. That should do it

Hi Boyan, when you say no diagonals, you mean to remove all angled box sections? and then swap my 5mm plate for 10mm on the existing bolt plates, the reason I chose 5mm was because it would be easier to weld to the 4mm box section (I think!)
Cheers, Charlie

**Boyan Silyavski** · 24-08-2015

Originally Posted by CharlieRam

Thanks for the quick replies guys.

Hi Boyan, when you say no diagonals, you mean to remove all angled box sections? and then swap my 5mm plate for 10mm on the existing bolt plates, the reason I chose 5mm was because it would be easier to weld to the 4mm box section (I think!)
Cheers, Charlie

Yes,
and if you do the small effort of designing and welding additional bottom plates where the threads will go, i am sure about that.

There is no problem welding 10mm plate to 4mm box section, on the contrary, the weld when properly done will make things stronger

Anyway, you could just buy 6m flat 10mm thick bar and cut it to many pieces with the Rage.

**CharlieRam** · 26-08-2015

I have been looking at the X drive and have modeled up what I have in mind, I was originally thinking twin motors but I didn't want to tie up a 4th drive, so if I go for the following method would the belt length cause too much issue (I have worked out the belt length and the nearest standard length from Zapp is 1895mm) and also would a nema 23 do it or should I go upto a nema34. In the first image the belt is housed in a 50x25 3mm thich channel, in the second I have moved it up to show the belt run. This gives me about 2mm inside the box section in all directions clearance. Should I expect more belt sag or whip , I am hoping if they are tensioned OK then it will be sufficient but as I have no experience of using belt drives I have no Idea!
Cheers, Charlie

**Clive S** · 26-08-2015

There is no problem using one motor I think most would use a nema34 in this case. You can buy the belts made to measure it might be an idea to have the belts lower down so as to be able to put long lengths of stock through the back etc.