Well here goes... Aluminium frame router design

[CharlieRam]

It's been a while so heres a little update.. been working on the Z axis and also repairing my mill in the meantime as I stripped the plastic gear on my Chester champion.

But it's not moving very freely, I have clocked the rails up within 0,01 and put it all together including the ballnut and tried to push it up the rails, I could just about move it but it didn't feel very nice, I took the plate off and greased the carriages, and tried the rails on there own. one felt lovely and smooth but the other felt notchy on one of the carriages. So I carefully removed the rail and it appears as though I have a ball bearing missing!

Would this cause a notchy/stiff feel in the carriage or have I got other problems? I measured one of the ball bearings and it was 3.98mm so am I right in assuming 4mm. This is the first time the rail has been off so it must of been missing when I got the rails and if it hadn't been for the notchy feel I wouldn't of taken it off so please no telling me off for removing it :-P

Cheers, Charlie

[mekanik]

Hi Charlie
When you get the carriage cleaned and running smooth, bolt the rails to your Z plate with the carriages installed but not bolted to matting face, offer the carriage/rail assembly up to your other plate and check the matting face with feelers to see if both plates are flat, one or both of the plates might be twisted or something.
Regards
Mike

[CharlieRam]

I've got to get the carriage running smooth first, I tried both carriages on each rail, one of the rails is perfect but on the other rail I have one notchy carriage, that is when i discovered what looks like a ball bearing missing, just wondering if anyone else has had a problem, I can buy some 4mm ball bearings and see if it makes a difference, it definitely doesn't feel right though.
PS. I did remove the rails from the Z axis to check I wasn't twisting it.