Small rigid router - Design advise needed

**Boyan Silyavski** · 29-12-2014

Originally Posted by GEOFFREY

Looking great, and your "shed" is to die for. G.

I noticed that too. Lucky man. Great development!

**mitchejc** · 29-12-2014

Thanks gents. The shed was actually build years ago as sort of an entertainment area which I started using as a workshop as there's just no space left in my garage. The tiled floor is a bit of a drawback because its not very flat and my wife still treats the area as hers so she does regular inspections for paint, glue and weld marks on the floor :-)

Have to say I did not realise that building the router was going to this much work! Everything is taking much longer than I thought but I'm enjoying every minute of it. Ahhh well ok not every minute but most of them.

**mitchejc** · 31-12-2014

After Jazz's stern but true words about over design I do feel a little bit guilty to continue posting pictures but heck, if its not right please comment, so we can all learn.

Completed the alu base plates that joins the gantry to the x rails. I've made the plates adjustable in both y and z direction so I don't have issues putting it all together later. Had the spacing of the ball nut mount wrong on my cad drawing so I had to make little adapter plates and pockets.

Ran a belt sander with 80 grit belt over the alu which did give it a rather rather nice brushed kind of finish.

Done and all holes drilled and tapped. Thought these we going take a few hours but ended up more than a days work

Like most of my parts the actual size of these surprised me when seeing them in the flesh and I probably could have gotten away with much thinner material?

**JAZZCNC** · 31-12-2014

Originally Posted by mitchejc

After Jazz's stern but true words about over design I do feel a little bit guilty to continue posting pictures but heck, if its not right please comment, so we can all learn.

NO NO please don't stop posting and my post wasn't aimed to discourage you or anyone else from building like this if they have capabiltys or means.
It soley to let those sitting on the side lines watching and wondering if this is the level they will have to build too know that it really really isn't.

You Sir are doing a marvelous job and for a first build I take my hat to you, thou I think you may have bushel in your thatch loose for doing it like this. . .Lol

Keep it up and don't let my rantings sway you it's the last thing I want.! . . . Just Like I don't want Newbies swayed away.!

**mitchejc** · 31-12-2014

Thanks for encouragement Jazz! The reason I felt a bit guilty was because I understood what you meant with your post e.g. I've seen this with air rifles as well were a few guys buy and post about extremely high end target rifles even thought they don't know which end should point forward and other newbies think that's what you need to have fun. After bonding the house and downgrading the car to buy a big $$$ gun they realize they actually had more fun shooting beer cans with the little budget plinker rifle they had. Now, I'm that guy that does not know sh%t but I'm still posting my stuff... :-) When all is done and dusted I'll post my "lessons learned" which will hopefully be helpful to other first timers.

Anyway, thanks, I only got great info and advice on here and I'm having a BALL trying to hack this beast together

>>> bushel in your thatch loose
Hehe, yes I get that often from friends. Why is someone considered nuts just because the they have the dedication and commitment of a suicide bomber towards their hobbies

**mitchejc** · 11-01-2015

A few more pics of progress on X.
Went with the Silyavski 8mm epoxy dams.

Thought I'd cast a T shape on my base to eventually use as reference to do initial setup of the gantry and Z. Things got out of hand as per usual and I had spare epoxy and did the whole base. Used modeling clay for the dams. VERY bad plan, don't do it. It works nicely to build the the dams but its a total bitc$%$ to remove the later.

base done

I made a little tent using a blanket and plastic sheet and stuck a little fan heater under there to get the temp up to about 50degC for proper post curing. You guys in the cold places might find that handy.

X sides painted light gray. The base is just white primer and is not going to be painted as it will be fully enclosed anyway.
X epoxy done and fully cured.

**mitchejc** · 11-01-2015

Finished the last work on the gantry before it goes on the machine.

Did the last bit of welding for the bottom plates and epoxy dams

When I did this it was raining everyday here in sunny South Africa so I had no choice but to spray inside. This reminded me why I hate to spray indoors. Managed to get it sprayed but also the floor, myself, my tool cupboards and everything else in the near vicinity :-)

starting to make things ready for the epoxy. Did not take photos of the epoxy process but you you know the drill.