MomusDesign

BENCHTOPCNCROUTERPLANS
Version 2.1
copyright 2013
All rights reserved
release date: March 30, 2013
www.momuscnc.com
v.
2.1
page
introduction
machinespecifications
designgoals
CNCbasics
CAD/CAMworkflow
explodedviews
designalterations
metalpartsfabrication
metalpartsassembly
woodpartsfabrication
woodpartsassembly
electronicsinstallation
coverinstallation
machinealignment
drawingsheets
169
suppliers
electronics
enclosure
epoxybedlevelling
spoilboard
preface
billofmaterials
structuraldesign
partslist&schedules
168
166
158
155
151
147
145
142
138
117
140
104
93
87
39
30
29
27
21
16
15
13
08
07
06
05
04
03
Xylotexinstallation
GeckoG540installation
limitswitches
Mach3setup
firstuse
171
ADDENDUM:Zaxisthrustbearing
02
tableofcontents
Thepurchaserofthisdocumenthasexpresspermission
fromtheauthortoprintahardcopyforpersonaluse
only.
Thisdocumentmaynotberesold,distributed,orused
forcommercialgain.Commercialsaleofcomponents
orassembliesderivedfromtheinformationhereinis
forbiddenwithoutpriorlicensingagreementwith
MomusDesign.
IFTHISDOCUMENTHASBEENPURCHASEDFROMANY
SELLEROTHERTHANMOMUSCNC,ITHASBEENAN
UNAUTHORIZEDANDILLEGALSALE.Pleasereportany
suchactivitytoMomusCNC.
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03
preface
Prefacetothe2ndedition
WelcometothesecondeditionoftheMomusDesign
CNCrouterplans.Themachinedescribedinthese
pagesisanevolutionandrefinementofanearlier
design,withnumerousandsignificantchanges
throughout.Theoriginalmachinewasdesignedand
constructedin20082009,withtheplansdebutingin
thesummerof2010.
Afterseveralyearsofusingthemachine,andfollowing
theprogressofotherswhowereconstructingtheirown
copiesfromtheplans,itbecameapparentthatthere
weremanyareasthatcouldbeimproved.Bythe
summerof2011itwasfeltthattherewereenough
desiredchangestowarrantafullredesignand
refinementoftheoriginalconcept.
Manyofthedesignimprovementsrepresentedinthis
secondeditionwouldnothavecomeaboutwithoutthe
inputandfeedbackofallthosebuilderswho
constructedthefirstversionofthemachine.Especially
significantwasthecommunicationbetweenbuilders
andmyselfthatwasmadepossiblebytheformationof
adedicatedsubforumonCNCzone.com
(http://www.cnczone.com/forums/momus_design_cnc_
plans/).Theexistenceofthisplatformhasbecomeand
integralandimportantaspectofboththisdesignand
theplansprogressingforward.Pleaseconsiderthisas
awelcomeinvitationtobecomeapartofthis
communityofbuildersandobservers.
BobPavlik
2012
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04
introduction
Introduction
Themachineplanscontainedinthisbookperhaps
bearonesignificantdifferencefrommanyothersthat
areavailable.Thedifferenceisthattheseplanswere
notputtogetherwiththegoalofsellingplans.They
arethebyproductofbuildingamachinethatcame
intoexistencebecauseoftheneedforafunctional
tool.
Thedesignandfabricationofthismachinewasdueto
aspecificneed,primarilythebuildingofmodelsfor
architecturalresearch,thatfocusedondigitaldesign
processesandconstructionautomation.Theinherent
natureofthisresearchrequiredtheuseofCNC
machinery.DespitehavingaccesstolargeformatCNC
equipment,theflexibilityofhavingahomeworkshop
basedtoolseemedtobegreatlyadvantageous.
Thedesignofthismachinebeganasmanyothers
surelydo:bystudyingexistingsolutionswiththe
intentofcreatingacopyofthebestcurrentlyavailable.
Unfortunately,noneoftheexistinghomebuiltsmall
formatCNCroutersseemedsuitedtomyparticular
needsandconstraints.Withasmallworkshopspace
available,limitedequipmentwithwhichtobuild,the
needtokeepdustandnoisecontained,andavery
meagerbudget,theexistingoptionswerequitelimited.
Sobeganthejourneyofdesigningandconstructingmy
ownmachine,aprocesswhichendedupconsuming
severalyears.Theresultingmachinehasfarexceeded
myinitialexpectations.Themachinehasperformed
superbly,provingcapableofmillingmaterialsnot
typicallyhandledbylowcostDIYmachines(suchas
aluminum,)andhavingaccuracythatfarsurpassed
originaldesigngoals.
Disclaimer:
Theauthorofthisdesignisnotaprofessionalengineer.This
manualoutlinestheconstructionofahobbyistmachine,designed
andbuiltbyahobbyist.
AlsonotethatCNCequipmentcanbedangerousmachinery.In
additiontotheinherentdangersofoperatinganypowertool,doing
soremotely,viacomputer,addsanotherlevelofpotentialdanger.
Errorsinprogrammingmachinemovementcanhavecatastrophic
consequences.
Itistheresponsibilityofthereadertousetheinformation
presentedinthismanualinamannerdeemedappropriateto
personaljudgmentandsafety,anduseatyourownrisk.
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05
Machinespecifications
MachineSpecifications:
MACHINESIZE
cuttingenvelope16x16x5.5
overallmachinesize32.5widex27.5deepx26tall.
ExactusableZaxistravelwilldependonexactconfiguration
ofroutermount,lengthofrouterbit,andthicknessof
spoilboardbeneaththeworkpiece.
MACHINECONSTRUCTIONMATERIALS
Machinebase:Plywood
Mechanicalparts:Aluminumandsteel.
Themachineisbuiltentirelyfromstandardstockmaterial
sizesofplywood,aluminumandsteel.Thestockmaterial
thicknessisusedforallcriticaldimensions.
Materialswerechosenforthisdesigninordertogivethe
highestpossiblemachinerigidityforthecost.NoMDF
(mediumdensityfiberboard)isusedintheconstructionof
themachine,asitistooflexibletoresultinamachineof
adequatestiffness.
DIMENSIONING
PlansaredimensionedinImperialmeasure.Theyare
NOTcurrentlyavailableinmetric.
Whiletheplansarenotavailableinmetric,numerous
machineshavebeenconstructedincountriesthatuse
metricmeasure.Thiscanbedoneeitherbyadapting
theplansforlocallyavailablemetricsizesof
materials,orbysourcingmaterialsfromtheUS(see
listofsuppliersattheendoftheplans.)
DRIVEMETHOD
XandYbeltdrive
Zprecisionacmeleadscrewwithantibacklashnut
Beltdrivecanuseeitheropenendedbeltingoraclosed
belt,dependingonavailability.Zaxisantibacklashnutis
acommerciallyavailableproduct.
LINEARMOTION
AllaxesarecontrolledbystandardABEC7bearingsriding
onrectangularcoldrolledsteelrails.
ADJUSTABILITYANDALIGNMENT
Allbearingsareprovidedwithamicroadjustablesetscrew
forpreciseandeasyadjustment.
Thedesignofthemachineisbasedaroundastepbystep
alignmentprocedure,thatallowsforhighlyaccuratesetup
withverysimpletools.
SPINDLE
Themachineisintendedtouseatrimrouter,suchasthe
BoschColt,orRidgidR2400/2401.
MACHINESPEED
Joggingspeedsofover500inchesperminute.
STEPPERMOTORS
NEMA23framesize.
Minimumrecommendedsize275oz./in.
RESOLUTION
At1/10microstepping:
XandYaxes.001
Zaxis.0000625
Notethatelectronicresolutionisnotanindicatorofthe
accuracyofthemachine.However,itisapotential
indicatorofthespeedofthemachine.Thefinerthe
resolution,theslowerthemachine.
MATERIALSTHATCANBECUT
Wood
Plastics
Foam
Aluminum
Brass
CircuitBoards
Notethatalthoughthemachineiscapableofcutting
aluminum,thismachineisdesignedandintended
primarilyasawoodrouter.Spindlespeedsoftrim
routersmaylimitthetypeofworkthatcanbe
accomplishedinmaterialsotherthanwood.
ACCURACY
Mechanicalaccuracy: +/.005
Precision(repeatability): +/.001
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06
designgoals
MachineDesigngoals
Whenthismachinewasdesigned,alistofgoalsandcriteriawereestablishedattheverybeginningofthedesign
process.Theoverallgoalwastocreateaninexpensivemachinethatcouldbefabricatedinahomeshopandperform
likeamachinecostingmanytimesmore.
Cost:
Themachineneededtobeasinexpensiveaspossible,whilemeetingasmanyothergoals.Targetbuildbudget
was$400,excludingelectronics.
Tools:
Constructionhadtobepossiblewithminimaltoolsandequipment.Ithadtobeconstructablewithbasictools
thatwouldnothaveahighlevelofaccuracyinthemselves.Thiswouldrequirecreativebuildtechniquesto
fabricateamachinethatwasmoreaccuratethanthetoolsusedtobuildit.
Accuracy:
Itneededtobeabletocuttoatoleranceofabout+/.005".Higheraccuracywasn'tdeemednecessaryasthe
machinewasprimarilyintendedtocutwood,whichisnotamaterialwithhighdimensionalstability.However,
ahighenoughaccuracywasrequiredtoallowmachiningofmatingpartsthatwouldbeassembled,which
requiresmoreaccuracythansimplycarvingorengravingasinglepiece.
Enclosed:
Duetowherethemachinewouldbeused,itwasnecessarytohaveafullenclosuretocontaindustandsound.
Speed:
CuttingspeedneededtobeconsiderablyhigherthanmostotherinexpensiveDIYmachines,whichoftenonly
movedat2030inchesperminute.Tofacilitaterunningprogramsthatcontainedtensofthousandsoflinesof
code,atargetspeedof150ipmwasset.
Alignment:
Manyexistinghomebuiltdesignshadnosimplewayofattainingaccuratemachinealignment.Aneasy
alignmentprocedurewasconsideredintegraltoasuccessfultoadesign.
Bindfree:
Asmanyexistingdesignshadnowayofbeingaccuratelyaligned,theyalsooftensufferedfrombinding.Linear
motioncomponentsthatcouldnotbebroughtintobeingexactlyparallelorinplanewouldcausethemachineto
bindduringtravelalongitsaxes.Thisbindingcouldcauseloststepsinthedrivemotors,potentiallyruininga
workpiece.
Selfcontained:
Allwiringandelectronicsshouldbeorganizedintoasingleunit,ratherthanhavingexternalcomponents.
Compact:
Toallowforeasyuseofthemachineatdifferentlocations,itmustrequirelittleornodisassembly/reassemblyfor
travel.
Attractive:
Themachinemustbeattractiveandlookmorelikeacommercialproductthansomethingthatwascobbled
together.
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07
CNCbasics
DesktopManufacturing
Whatwasonceatechnologythatexistedstrictly
withinindustry,CNC(ComputerNumericControl)
equipmenthasincreasinglyfoundwidespreadusein
thehomeworkshop.Atitsmostbasic,CNCisa
methodofusinganumericalcodetocontrola
machine.Nearlyanytypeofmachineor
configurationcanbecontrolledthisway.Ifithasa
rangeofmovement,whetherlinearorrotary,itcan
becontrolledbyanumericalcodethatinstructs
thosemovements.Therefore,CNCcanbeusedona
widespectrumofequipment,suchasmilling
machines,lathes,plasmacutters,waterjets,hotwire
foamcutters,wireEDM,etc.Or,asisthecasewith
theseplans,a3axiswoodrouter.
IntheearlydevelopmentofCNC,thenumbersthat
wereusedtocontrolamachinewerehandcoded
andpunchedintoapaperrollthatwasfedthrougha
mechanicalreader.Thepunchedholesequatedto
discretemovementsteps.Whileprogramming
simplemovements,suchasstraightlines,waseasily
accomplished,curvedorfreeformgeometrywas
muchmoredifficulttoachieve.Withthesecomplex
shapes,thesmallerthedistancebetweenthemotion
steps,thesmoothertheresults,necessitatingthe
calculationofthousandsofmovementpoints.With
theadventofthecomputercametheabilityto
generatemuchmorecomplexnumericalcode,
resultinginverysmoothmachinemotions.
Morerecentlytherehasbeenatremendousgrowth
inDoItYourself(DIY)homebuiltCNCequipment.It
isnowarelativelystraightforwardprocessto
generatethecode(GCode)tocontrolaCNC
machinetoolonahomePC,andoutputthesignal
throughaparallelportorUSBporttomotioncontrol
motors.Dependingonhowcomplexand
sophisticatedthegeometryofthepartsbeing
manufactured,thiscanevenbeaccomplishedwith
freesoftware.
Thepotentialimplicationsforthisrevolutionindesktop
manufacturingarehuge.Transferringthemanufacture
ofextremelycomplexpartsfromcostlyindustrial
settings,whichwastheonlyoptionintherecentpast,to
alowcosthomeshopopensupaworldofpossibilities.
Manyofthemachinesthathavebeenconstructedfrom
theplansinthismanualhavefounduseinsmallhome
basedmanufacturingbusinesses.
However,havingtheabilitytoeasilyhavethese
manufacturingcapacitiesavailableraisesquestionsof
appropriateuseoftechnology.Ifapartcanadequately
bemadebymoretraditionalhandcraftedmethods,it
maybeaninefficientuseoftimeandresourcestousea
computercontrolledmachine.Inadditiontotheinitial
timeinvestedinmachineconstruction,thefabricationof
apartcanrequiresignificanttimespentatthecomputer.
Evenasimplepartrequiresdrawingor3dmodelingit,
decidingonamachiningstrategy,generatingtoolpaths
andGcodefromthedrawing,andsettingupthestockto
becutonthemachine.
Theadvantagescomesinusingtheequipmentfor
purposesthatcannotbeachievedeasilybyothermeans.
CNClendsitselftojobsrequiringhighlevelsofaccuracy,
consistencybetweenrepetitiveparts,andcutting
complexgeometries.Theseadvantagesaresignificant,
andpotentiallytransformative,forbothhobbyand
businessuse.
DESIGN(CAD)
TOOLPATHS(CAM)
MACHINECONTROL
Designpartsinsoftwaresuchas
AutoCad,Rhino,Solidworks,
TurboCad,etc...
Generatemovementofthe
cuttingtoolinsoftwaresuchas:
MasterCam,RhinoCam,
BobCad/Cam,etc...
Sendcuttingtoolinformationto
themachinewithsoftwaresuch
as:
Mach3,emc2,TurboCNC,etc..
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CAD/CAMworkflow
CAD/CAMWorkflow
Designingpartstomill
Partsthatultimatelywillbecutwiththemachineneed
tooriginatesomewhere,andthattypicallyhappens
withinsomesortofCAD(ComputerAidedDesign)
softwaresuchasAutoCad,Rhino3d,Solidworks,
AutoDeskInventor,TurboCad,orevensoftwaresuchas
Coreldraw.Thissoftwaremaybeeithera2dor3d
environment.Thetypeofsoftwarerequiredwillbe
driveninlargepartbythetypeandgeometric
complexityoftheworkbeingdesigned.Verysimple
partsthatarebeingcutfromsheetstockcanbe
designedinveryrudimentarysoftwarethatmerely
allowsyoutoaccuratelydrawtwodimensionallinesand
exportthatinformationinanappropriatefileformat.
Cuttingpartsofthisnatureisoftenreferredtoas2
axismilling,asmostofthemachinemotionhappens
withinonly2axis.Thespindleonlymovesupanddown
intheZaxistoentertheworkatthebeginningofthe
cutandtoliftitselfclearofthematerialattheend.
Simplepartscanbedesignedinoneofthemany
freeware2ddraftingsoftwarepackagesavailable,as
longasthedesigncanbeexportedinafileformatthat
iscompatiblewithothersoftwarethatwillbeused
downstreamintheworkflow(theCAMsoftware).
Creatingthegeometryforcomplexthreedimensional
surfacesrequiresamuchmoreadvancedsoftwarethan
isnecessaryforsimple2dlinework.Softwaresuchas
Rhino3d,Solidworks,orInventorarepowerful3d
modelingtoolsdesignedspecificallytomanipulate
sophisticatedtopographicalgeometries.Cuttingthese
surfacesisconsideredfull3dmilling,astheZaxisof
thespindleismovingincarefulcoordinationwiththeX
andYaxestoresultinthedesiredshape.These
surfacesareexportedinfileformatsthatpreservetheir
topographicaldata.
Toolpaths
ThenextstepintheCAD/CAMworkflowistypicallyto
generatetoolpaths,orthemovementsofthemachine
thatarenecessarytocutyourpart.Thiscanhappenin
CAM(ComputerAidedManufacturing)softwaresuchas
Mastercam,RhinoCam,MeshCam,MadCam,orarange
ofotherprograms.Thefollowingarebasicstepsthat
areoftenpartoftheworkflowwithinaCAMsoftware
package.
1. Machinedefinition.
Thesoftwareneedstoknowtheconfigurationofthe
machineitself.Whilemanyofthemorebasicprograms
areonlycapableof3axismilling,moreadvanced
softwarecanhandlemoremachineaxes,oralternate
configurationsofhowthoseaxesmove.
2. Stocksetup.
Thesoftwareneedstoknowhowlargeyourpieceof
stockis,sothatitcancalculatehowmuchmaterial
mightneedtoberemovedfromaroundthefinalpart.
Thisislessimportantinbasic2axismilling,whereit
oftenreallydoesnotmatterhowlargethestockmight
be,aslongasitissufficientlylargetoallowclampingto
themachinebedatasafedistancefromthecutting
path.Stocksizeismuchmorecrucialwhendoingfull3
axismilling,astheincreasedamountZaxismovements
createsmoreopportunitiesforcollisionbetweenthe
cuttingtoolandthestock.Soagain,thisisasituationof
needingtomatchtheabilitiesofyoursoftwaretothe
typesofpartsthatyouwanttomake.Complicated
partsmayevenneedtohaveadditionalgeometrydrawn
inthedesignsoftware,toprovideadditionalcutting
surfacestoremovematerialforneededtoolclearance.
Thereareacoupleoftypicalwaystoenterstocksize
informationwithinCAMsoftware.Oneistoenter
coordinatesforthecornerpointsofyourstocksize.
BetterCAMsoftwarecanautomaticallydetectthe
boundarysizeofyourpartandgenerateastocksize
aroundthat.Inthiscase,itisoftendesirabletodraw
theuncutblockofmaterialinthedesignsoftware,so
thattheCAMsoftwarecreatesthedesiredmaterialsize.
CAD=ComputerAidedDesign
CAM=ComputerAidedManufacturing
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CAD/CAMworkflow
3. Toolsize.
Thesoftwareneedstoknowthediameterandshapeofthe
cuttingtool.ManyCAMpackageshavealibraryoftoolsfrom
whichyoucanpickthesizeandshapeofyourcuttingbit.In
othersyoumayneedtoenterthisinformationmanually.
4. Cuttingspeedsandfeeds.
Dependingonnumerousfactors(thetypeofmaterialbeingcut,
thetypeofcuttingtool,therpmspeedofthespindle,howmuch
ofthetoolisbeingengagedinthematerial,andthequalityof
finishdesired),thefeedratemustbesetforhowfastthetoolis
pushedthroughthematerial.Onmosthomebuiltmachinesthe
spindlespeedissetattherouteritself,sothatdoesnotneedto
becontrolledthroughthesoftware.Thefeedratemustbefast
enoughthatthetoolcanefficientlyejectthecutmaterialaway
fromthecuttingarea.
Therearetwomethodsofdeterminingfeedrates.Thebest
methodistodoachiploadcalculation,whichtakesallofthose
factorsaboveintoaccount.Theprincipleofthiscalculationis
thatitprovidesforanidealquantityofmaterialtoberemoved
bythetool'scuttingedgeeachtimeitmovesthroughthe
material.Thisquantityisoftenpublishedbythemanufacturer
ofthecuttingtool.Thiscalculationwillgiveafairlyaccurate
numberforsettingfeedrate.
Theothermethodisanempiricalprocess,whereexperiencecan
provideanequallygoodfeedratenumber,orcanaidinfine
tuningthenumberthatisarrivedatbyachiploadcalculation.
Unfortunately,inpracticemanyotherhomebuiltmachines
requireneithermethod.Theytypicallyhaveamaximumtravel
speedthatisfarbelowrunninganydangerofgoingtoofast.So
theycanoftensimplyberunatthehighestfeedratethatthe
machinewillallow.Ifanything,manyhomebuiltmachines
oftenhavetheproblemofrunningsoslowlythattheycancause
apoorsurfacefinish,orevendamagetothepartorcuttingtool,
becausetheydonotremovematerialquicklyenoughtokeepthe
cuttingedgecoolWhencuttingwoodthiscancauseburningof
thematerial.
5. Toolpaths.
Thenextstepistypicallytogeneratetheactualpathsthatthe
toolwillfollow.Withsimple2axiscuttingthisisaverysimple
processwithoutmanyfactors.Primarilyallthatmattersisthe
sizeofthetool.Morecomplex3dcutsopenupawiderarrayof
cuttingoptions.Complexpartsmayrequiredetermininga
logicalcuttingstrategy,toremovematerialinaseriesofstages
thatwillresultinthebestsurfacefinishorrequiretheleasttime.
Roughingvs.Finish
Whenremovinglargeamountsofmaterialquickly,a
roughingcutisoftenused.Thisisafairlyaggressivecut
designedtoremovestockaroundthefinalgeometryquickly
andefficiently.Itmayhavethetipofthetoolengageddeep
intothematerial,andwhenmultipleparallelpassesare
requireditmaystepoverasfarastheentirediameterof
thetoolbetweeneachpass.Theroughingcutwilltypically
thenbefollowedbyafinishcutwhichremovesamuch
smallerfinalamountofmaterial,bothindepthofcutand
distanceofstepoverbetweenpasses.Theremayevenbea
changeofcuttingtoolsbetweentheroughingandfinish
cuts.
Plunging
Whenmillingpartgeometrieswherethetoolcannotsimply
entertheworkpiecefromtheedgeofthestock,suchas
whencuttingapocket,thetoolneedstomakesometypeof
descendingcutintothematerial.Thesimplestmethodisto
movethetoolstraightdownintothematerial,whichmay
ormaynotbethemostappropriatemovement.Many
cuttingtoolsarenotdesignedtobeplungedstraightdown
intomaterialinsuchaway.Atoolthatcanaccommodate
thismoveisreferredtoasendcutting,andcancutonits
tipaswellasitsside.Whenthetoolcannotbeplunged,the
tipwillneedtobegraduallyloweredintothestockasitis
simultaneouslymovedinasidewaysdirection.Thisis
calledrampingintothematerial.ThebestCAMprograms
providegreatcontroloverhowthetoolcanberamped
downintothematerial,includingstraightrampingand
helicalmoves.Itmayalsobedesirabletoavoidstraight
plungecutsduetomaterialproperties.Thegrainofsome
woodsmaytearundersuchatoolmovement.
Directionofcut
Anyamountofexperiencewithahandheldrouterwill
quicklyrevealthedifferencebetweenmovingthetoolfrom
lefttorightandrighttoleftalongtheedgeofapieceof
material.Onedirectionwillbemuchhardertocontrol.
Withahandheldrouteryouwouldtypicallymoveleftto
righttomaintainthegreatestcontrolofthetool.Thisis
calledconventionalmilling.Ifmovingintheother
direction(climbcutting)therouterbitmaygrabintothe
materialandbepulledinanundesirabledirection.
However,whencontrollingtherouterwithamachinethe
situationisnotsosimple.Dependingonthecircumstances,
climbcuttingmayprovideamuchfinersurfacefinish.
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CAD/CAMworkflow
6. Simulation.
ManyCAMprogramshaveasimulationfeaturewhichwill
allowviewinga3dcomputersimulationonthecomputer
screenofthetoolcuttingthematerial.Thiscanallow
watchingifthetoolismovingindesireddirectionsand
sequences,andifthereareanypossiblecollisions
betweenthemachineandthestock.ThebestCAM
programswillautomaticallydetectthesecollisionsand
provideawarning.
7. Postprocessing.
Oncealloftheabovestepshavebeenfinalized,andthe
operatoriscontentwiththetoolpaths,thefinalstepis
postprocessing.Thisiswherethesoftwareconverts
allofthetoolpathinformationintoaformatthatcanbe
readbyothersoftwarethatwillcontrolthemovementsof
themachineitself.Thisistypicallysomevariationofan
industrystandardlanguagecalledgcode,whichisa
simpletextfile.Gcodeisnothingbutalinebylinesetof
numericalinstructionsforthemachinetofollow.Itgives
toolmovementinformationinabsolutecoordinates,and
mayalsoprovideinformationsuchasfeedrateand
spindlespeed,andonmoreadvancedequipment,moves
suchasautomatictoolchanges.
WhileGcodeisastandardlanguage,unfortunatelyeach
machinecontrollersoftwareoftenusesitsownvariation.
Themachinecontrolsoftwaretypicallyusedbythehome
builderrunsonaversionthatisoftenveryclosetopure
(canonical)gcode.Morespecializedmachinery,which
hasitsowncontrolelectronicsratherthanusingaPCfor
control,oftenhasacorrespondinglymorespecialized
versionofgcode.
Similartotheneedformatchingthedesignsoftwareto
thetypeofpartsthatyouwanttocreate,itmaytake
somenecessarycaretomatchCAMsoftwaretocontrol
software.Problemsmaybeencounteredwithfinding
CAMsoftwarethatcanhandlegeneratingtoolpathsfor
complexgeometry,yethasproperpostprocessingability
forcontrolsoftwaresuchasMach3oremc2,whichare
typicalofwhatisusedbythehomeuser.Softwarethat
willaccommodateverycomplexgeometrymayonlyhave
postsavailableformoreindustrialmachinecontrols.This
mightmeanlearningenoughgcodetobeableto
manuallyeditandalterpostprocessedcodeforuseinPC
basedcontrolsoftware.
MachineControlsoftware
Mach3,emc2,TurboCNC
Thissoftwaretakesthecodethatwasgeneratedbythe
CAMsoftware(gcode)andoutputsitaselectronicsignals
thatactuallycontrolthemotorsonthemachine.This
typicallyhappensbysendingpulseanddirection
signalsthroughaparallelportcabletothemachine
electronics.Mach3hascometodominatetheDIYCNC
market,asitisaveryrobustprogramandisaffordably
priced.Manypeopleusethefreedemonstrationversion
ofthesoftware,butitisrecommendtopurchasethefull
versioniffundsallow.Thedemoiscrippledtorunning
500linesofcode.Thismightseemlikealot,andmightbe
sufficientformillingverysimplepartswithmostlystraight
cuts,butitwillquicklybefoundtobeseverelylimitingfor
cuttinganythingmorecomplex.Evensmallpartswith
verycomplex3dshapesmayeasilyrequiretensoreven
hundredsofthousandsoflinesofcode.Anotherless
known,butjustasimportant,restraintofthedemo
versionisthatitlimitstheprocessingspeedofhow
quicklyitoutputssignalstoyourmachinesmotors.This
candirectlylimitmachineperformance.
Softwareoverlap
Often,softwareuseisntquiteasdirectastheworkflow
diagrammightindicate.ManyCAMsoftwareprograms
providetoolsfordoingbasicCADwork.Whilethiscanbe
handyformakingminorchangesafterimportinggeometry
totheCAMprogram,itisrarelypowerfulenoughtouseit
asthesoledesigntool.Anythingmorethanminor
changesarebestdonebackintheoriginaldesign
software,andthenreexportedtotheCAMprogram.
Similarly,controlsoftwaresometimeshasbasictoolsfor
conversionof.dwgformatlinedrawingstogcode.Again,
thisisnttheprimaryjobofthesoftware,sowhileitmay
workadequatelyforverysimplejobs,itshouldnotbe
reliedonexclusively.Controlsoftwaretypicallyalso
containsagcodeeditorformanipulationofthecode.
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CAD/CAMworkflow
Costofsoftware
Asmightbesurmisedbythispoint,thecostofthe
softwarenecessarytodesign,generatetoolpaths,and
thencontrolthemachinecanbevery,veryexpensive,
especiallyifneedingtocreatepartsofanycomplexity.
BeforeconstructingaCNCmachine,itishighly
recommendedtolookintothecostsofthesoftware
programsthatmightberequired,astheycaneasilyfar
exceedthebudgetformachineconstruction.Most
softwarevendorshavefunctioningdemonstration
versionsavailablefordownload,anditisalso
recommendedtotrythembeforepurchasing.Someare
muchmoreuserfriendlyandintuitivethanothers,
whichhaveverysteeplearningcurves.
Whilesoftwarewithadvancedfunctionalitycanbevery
expensive,thereisasubstantialandgrowingquantity
oflowerbudgetprogramsavailable.Someoftheseare
evenfree.Whiletheyareoftenlackingcertainfeatures,
asignificantamountofcomplexworkcanoftenbe
achievedwiththenbyemployingsomecreativityinhow
theyareused.Workaroundscanoftenbediscovered
thatcancompensateforfunctionalitythattheymay
lack.Thesupplierlistattheendofthismanual
includesalistofsoftwaresuppliers.
LearningGcode
Anotheralternativewhencuttingsimplepartsisto
handwritegcode.Doingthiscaneliminatetheneed
forbothdesignsoftwareandCAMsoftware.Before
thedevelopmentofsophisticatedCAMsoftware,this
washownumericmachinecontrolcodewasgenerated.
Thenumberofapplicationsofthistechniqueare
probablylimitedthesedays,butitcanbeauseful
methodtoknow.Evenifhandwritingnumericcodeis
notaprimaryworkingmethod,understandingtheG
codelanguagecanbeusefulasitcanallowquick
editingormodifyingpartsofthecodesuchasfeed
rates,withouthavingtogothroughthepost
processingstepagain.Combinedwithothercomputer
programmingskills,learninggcodecouldalsoallow
writingscriptstogeneratetoolpathsandgcodefrom
within3dmodelingsoftwaresuchasRhino.
computer
motordrives&
powersupply
machinemotors
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machineelectronicsbasics
Electronics
Whileanindepthdiscussionofmachinecontrolelectronics
hardwareisbeyondthescopeoftheseplans,anoverviewis
importantforabasicunderstanding.Forthemostpart,this
discussionwillstaysomewhatabstract,althoughinthe
machineassemblyinstructionsthespecificinstallationoftwo
typesofdriveboards,aXyoltexandaGeckoG540,willbe
covered.Duetothecomplexityofchoosingindividual
componentsthatwillfunctionwelltogether,itishighly
recommendedtopurchaseaprepackagedkitfromasupplier
thatincludesalloftheelectronicsasamatchedcollection.
Whilespecificcomponentsofanelectronicdrivemotion
controlsystemforahomebuiltCNCmachinecanvarywidely,
theabstractdiagramtotheleftillustratesthebasicprinciples
ofwhatisincluded.
Ingeneral,theseare:
1. Acomputertosendmotiondatatoahardwarecomponent
calledamotordrive.
2. Apowersupplytoprovidetherequiredvoltage&current
tothemotors.
3. Electronicmotordrive(s)thatforwardsthemotiondatato
themotorsattherequiredvoltage/current.
4. Themotors.
Thisisthegeneralflowofinformationfromthecomputerto
themotors.Inaddition,therearetypicallyhardware
componentstoprovidedatafeedbackfromthemachineto
thecomputer.Allsystemsshouldbeequippedwithlimit
switchesattheendofeachaxistravel,toprovidesafetyto
boththemachineandoperator.Moresophisticateddrive
systemsmayhavefeedbacksensorsthatgivemoreaccurate
controlofthemotorpositioning.
Workingbackwardsfromthemotionofthemachine:
Motors
Mosthomebuiltmachinesarecontrolledbysteppermotors.
ThesearesimpletypeofDCmotorthatrequiresapulseof
electricitytomoveitonestep.Atypicalsteppermotorhas
200stepsperrevolution,sotocausecontinuingrotationina
steppermotoritrequiresafaststreamofdiscreteelectrical
pulses.Thefrequencyofthepulseswilldeterminethemotor
speed.
Thesemotorsareeasytoelectronicallycontrolviacomputer,
andrelativelyinexpensive,buttheydohavesomedrawbacks.
Oneisthatthereisthepossibilityofthemlosingsteps
underaload.Thishappensduetothestreamofelectricalstep
pulsescontinuingtoflowtothemotoreventhoughitis
temporarilybeingpreventedfrommoving.Sincethenumber
ofstepsrequiredtomovethemachineisveryhigh,averysmall
numberofmissedstepsmaynothaveanynoticeableimpact
onthefinishedpart.Ontheotherhand,enoughmissedsteps
maybecatastrophic.Inthebestcase,itmayresultinaless
thanperfectpart,andattheworstitmayresultinmachine
collisions,sinceaftertheeventthatcausesloststepsthe
machinelocationisnotcorrespondingtowherethesoftware
thinksitshouldbe.Missedstepsisaproblemwithstepper
motorsbecausetheytypicallylackanysortoffeedback
mechanism.Theysimplydoastheyaretold,andthecontrol
softwarehasnowayofrecognizinganyerrorthatmayoccur,
orwayofcorrectingthemotion.Somemoreadvanced
systemsemployasensorthatinformsthesoftwareofthe
positionofthemotorormachine,sothatitcancompensate
foranydeviationandreturnittoproperlocation.
Anotherproblemthatsteppersoftensufferfromismid
bandresonance.Thisoccurswhenthefrequencyofstep
pulsescausesadynamicresonancewithinthemotor.This
maycauseittomoveerraticallyorevenlockupcompletely.
Thisisobviouslyanevenbiggerproblemthanafewmissed
steps.Somestepperdriveshavecircuitrythatisdesignedto
combatthisphenomena.Manyhobbyleveldrivesdonot.
Manyindustrialmachinesuseservomotorsratherthan
steppers.Theydonotrunindiscretestepslikeastepper
motor,butratheraremoresimilartoaconventionalmotor
design.ThesecanbeeitherDCorACdesigns,andtypicallyrun
atamuchhigherrpmthansteppers,necessitatingagear
reductionofsomesort.Duetobothofthesefactors,servo
motorsconsequentlyhaveamuchsmootheroperationthan
steppers.Themajoradvantageofservosisthattheytypically
haveapositioningfeedbackloop.Theyemployadevicecalled
anencoderthatmonitorsthepositionofthemotor.Any
discrepancybetweenthetheoreticalpositionofwherethe
motorshouldbe,andwhereitismeasuredasbeing,canbe
compensatedfor,andbroughtbacktothecorrectposition.
However,servosarestillmuchmoreexpensivesystemstoset
uponahomebuiltmachine.Theyrequiremoresophisticated
electronicsequipmenttodrivethemandmoreknowledgeto
setthemupandtunethem.
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electronics
Torquecurve&powertransmission
Likeallelectricmotors,steppermotorshavethecharacteristic
ofproducingthegreatestamountoftorqueatzerorpm.
Whatthismeansisthatthefasterthemotorturns,theless
forceitproduces.Manufacturersprovidegraphsthatshow
theirmotorstorqueoutputrelativetorpm.Notallmotors
arecreatedequal,assomehavetorqueoutputthatfallsoff
muchmorequicklyrelativetorpmincreasethanothers.
Therefore,whendesigningapowertransmissionsystemitis
crucialtoknowwhatrpmthemotorwillbeturningforagiven
movementspeedatthemachine.Gearingdownthesystem
maynotnecessarilyincreasethemachinespowerasthe
decreaseinthemotorsavailabletorqueatahigherrpmmay
begreaterthanthemechanicaladvantagethatisgained
throughgearreduction.However,eventhoughthemotor
producesmosttorquewhenbarelyturning,themachine
cannotbegearedtomaintainthemotoratthatspeed.Ifthe
motoristurningthatslowlythenthedistancebetweeneach
stepofitsmovementwilltranslatetotoolargeofa
movementatthecuttingtool.Itwillnothaveafineenough
cuttingresolution.Sothesystembecomesacompromise
betweenseveralfactors.
Thebeltdrivesystemonthismachinewasdesignedwith
exactlythesefactorsinmind.Itisfelttobeagood
compromisebetweenmachinespeed,poweravailableto
pushatoolthroughthematerialitiscutting,andavoiding
motorspeedsthatwouldbevulnerabletomidband
resonance.
Abeltdrivewasalsofelttobeadvantageousoveralead
screwsystemforthismachineasitismoretolerantof
misalignment.Aleadscrewmustbealignedexactlyparallel
tothemachineaxisitispowering.Bycontrast,thebeltcan
beoutofalignmentbyasignificantamount,withzero
negativeimpactonmachineaccuracyorperformance.Note
thatmisalignmentwillhaveasignificantnegativeimpacton
beltwear.
Drives
Allmotorsthatareusedformotioncontrolrequiresometype
ofelectronicdriveboardtocontrolthem.Driveboardstakea
varietyofarrangements.Theymayincorporatecontrolfor
severalaxesonasingleboard,ormaybeconfiguredasan
individualboardforeachaxis.Theadvantageofanseparate
boardperaxisisthattheycanbereplacedindividuallyincase
ofdamage.
Alldriveboardsdoessentiallythesamething.Theyreceive
inputsignalsfromthecontrolsoftware,whicharelowin
voltageandcurrent,andinturnoutputthesesignalstothe
motorswithhighervoltagesandcurrentsthattheyrequirefor
operation.Assuch,theymediatebetweenthecomputerand
themachine.Theirinbetweenpositionalsoallowsthemto
handlesignalinputsforadditionalfunctionssuchas
emergencystopbuttonsandlimitswitches.Mostdrive
boardsareveryvulnerabletoanyerrorsinmiswiring.
Incorrectconnections,orbreakingaconnectiontothe
motorswhileunderpower,cancauseanimmediate
destructionoftheelectronicsontheboard.Follow
manufacturerdirectionsvery,verycarefully.
Microstepping
Anotherfunctionofmanydrivesisthattheybreakupthe
numberofstepsperrevolutionthatarerequiredatthemotor
intoagreaternumber.Soforinstance,adrivemayhave
1/8or8xmicrostepping,whichwouldeffectively
increasethenumberofstepsperrevolutionthatcontrolthe
motorfromitsoriginal200to1600.Thisisadvantageous
inthatitincreasestheresolutionofthesystemandprovides
finercontroloverthemovementofthemachine.Notethat
thesemicostepsaretypicallynotanexactlyequalsub
divindingoftheoriginal200steps.Eachmicrostepmayvary
fromtheothersbyaverysmallpercentage.Thisdiscrepancy
istypicallysosmallthatitisinconsequentialandwillnot
adverselyeffecttheaccuracyofthemachine.However,when
includingmicrosteppinginthecalculationofmachine
resolution,itshouldbeunderstoodthatthisnumberhasa
veryslightvariabilitywithinit.
Powersupply
Thisisassimpleasitsounds.Atransformertypepower
supplydeviceismatchedtotheneedsofthedriveboard(s)
andmotors.Itisworthnotingthatmanyboardsthat
operatebypulsewidthmodulation,suchastheXylotex,
actuallyperformmostefficientlyattheupperlimitsof
voltagethattheycanhandle.Inotherwords,runningthem
atlowervoltagewillnotnecessarilyprovideanyadditional
protectionforthedriveboard.Steppermotorsalso
commonlyrequiremanytimesmorevoltagethantheir
ratingsmayindicate.Forinstance,asteppermotorthatis
designatedasa2.5voltmotormayrequirea24voltpower
supplytoefficientlypowerit.
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electronics
Breakoutboard
Simpledriveboards,suchasthosethathavemultipleaxes
selfcontainedonasingleboard,maybedesignedfordirect
connectiontothecomputersparallelportviaastandard
cable.Whenusingmultipledrivesthateachcontrolan
individualaxis,anadditionalpieceofhardwarecalleda
breakoutboardmayberequired.Thisismerelyadevice
thatconnectstothecomputerviaacable(typicallyparallel
port)andthenprovidesmultipleconnectionstoallowwiring
tothedrives,emergencystopstopswitches,limitswitches,
spindlecontrolrelays,etc.Theseboardsalsooftenprovide
anaddedlayerofprotectionbetweenthehighervoltagedrive
boardsandthevulnerablelowvoltagecomputer.Theydo
thisthroughopticallyisolatedconnections.
Additionalswitches
Driveboardsorbreakoutboardswillfurnishsomemeansof
wiringinseveralimportantadditionaldevices.Anemergency
stopbuttonshouldbepartofeverysystem.Itistypicallya
largeredbuttonwithamushroomshapedhead,thatprovides
animmediatewayofshuttingdownthemachineincaseof
anemergency.Itshouldbeplacedinalocationthatiseasily
accessiblewhileoperatingthemachine.Itcanbewiredto
shutdownallaxesofmachinemovement,andcanusually
alsobewiredtoshutdownpowertotheroutertokillthe
spindlemovement.Ifatallpossible,yourestopbutton
shouldbewiredinthismanner.
Theotherswitchesthatshouldbewiredintothesystemare
limitswitches.Theseareplacedattheendofeachaxiss
rangeofmovement,thusa3axismachinewilltypicallyhave
6switches.AlimitswitchontheZaxis,inthedirectionof
movementtowardthemachinebed,maybeomittedasit
wouldrequirefrequentrepositioningduetochangesinstock
size,cuttingtoollength,etc.Theseswitcheswillstopthe
motionofthemachineifitunexpectedlyreachestheendofa
travelaxis.Thiscanpreventseriousdamagetothemachine
aswellasguardingagainstpersonalharmfrombroken
cutters.Inadditiontoactingassafetydevices,these
switchescandodoubledutyashomingswitches.Theseare
usedtoreturnthemachineautomaticallytoitshomeXYZ
position.Mostcontrolsoftwarecanbeconfiguredtousethe
switchesinthismanner.
Thecomputer
Alloftheseinputsandoutputseitheroriginateor
terminateinthecontrolsoftwareinthecomputer.Most
controlsoftwareforhomebuiltmachinesiswrittentobe
usedonPCs,althoughMacversionsarebecoming
available.Themostpopular,Mach3,isdesignedfor
Windowsbasedmachines,andotherssuchasemc2are
Linuxbased.Acomputerwithaparallelportforoutput
tothemachineelectronicswilltypicallyberequired.The
computerneednotbethelatestmodel,andinfactan
oldermodelwithWindowsXPorevenWindows98may
bepreferablewithsomesoftware.Adesktopmodelis
generallybetterthanalaptop,asmostlaptopsdonot
haveahighenoughvoltageoutputthroughtheirparallel
ports(iftheyevenhaveone)toperformwell.Theyalso
oftenhavepowersavingfeaturestoextendbatterylife,
whichinterferewiththepulsetimingofthecontrol
software.
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soundcontrol
Machineenclosureandsoundtransmissionprinciples
Oneoftheimportantconsiderationswhiledesigningthis
machinewasthenecessityforittobeenclosed,forthe
containmentofbothdustandnoise.Therearemany
existingexamplesofhomebuiltmachinesthathavealso
includedacoverforthesereasons.However,there
generallyseemstobeafundamentalmisunderstandingof
thebasicprinciplesofsoundcontrol.Thisisevidencedby
thetechniquethatmanyofthesebuildershaveadopted:
liningtheinsideoftheenclosurewithfoamrubber
acoustical"insulationofthetypewithaneggcrate
texture.Unfortunately,thisisanincorrectapplicationof
thismaterial.
Thereareacoupleofdifferenttypesofsoundcontrol.First
isthecontrollingofsoundwithinaspace.Soundwaves
bounceoffofsurfacesanditisoftendesirabletohavea
certaintypeofcontroloverhowthishappens.Themore
timesasoundbouncesoffofsurfacesbeforeitreachesa
listener'sear,thelongerthereverberationtimeis
consideredtobe.Sometimesalongerreverberationtimeis
desirable,suchasinaconcerthall,andatothertimesa
shortorzeroreverberationtimeisneeded,suchasina
recordingstudiowhichmustbefreeofechoes.Liningwalls
andceilingswithamaterialthatabsorbssoundwaveswill
preventthemfrombeingreflectedbacktoalistener,and
makesthespacemoreacousticallydead.
Theothertypeofsoundcontrolisbetweenadjoiningspaces.
Thisissoundtransmission.Anexampleofthiswouldbea
situationsuchasadjoiningroomsinabuilding,whereitis
desirabletohaveaslittlesoundmakeitswayfromoneroom
toanother.Thisisacompletelydifferentsituationfrom
controllingsoundwithinaspace,andthisisthetypeof
soundcontrolthatthemachineenclosuremustprovide,
preventingthetransmissionofsoundthroughit.Thefoam
insulationusedbymanybuildersisnotintendedtocontrol
soundtransmission,thereforeitwouldbeofsignificantuse
onlyifalistenerwereplacedinsidethemachineenclosure.
Otherwise,itwillmostlyservetocollectalotofdust.
Therearethreeprimarycategorieswithwhichsound
transmissioncanbecontrolled:
1. Distance
2. Isolation
3. Mass
Thefirstcategoryisobvious.Thefartherawayasoundis
placed,thequieteritisgoingtobe.Thiscategoryclearlyisnt
ofmuchhelpindesigningamachine,asitcan'tsimplybe
placedfartheraway.
Thesecondcategoryisveryimportantwhenitcomesto
machinery.Vibrationscanbetransmittedthroughmaterials
andcausenewvibrationstobeproducedadistanceaway.
Thesenewvibrationsproducesound.Tocombatthis
tendency,manypiecesofequipmenthaveisolationmounts
thatdampvibrations.Thesemaybecomprisedofsprings,
hydraulicdevices,orelastomericmaterialssuchasrubber.
Evenifallsoundcouldbecontainedwithinanenclosure,
boltingthemachinerigidlytoabenchcouldhavetheeffectof
turningthebenchtopintoalargesoundingboard.
Thethirdcategoryistheonethatisofprimaryimportanceto
thisdesign.Increasingmassisaveryeffectivewayof
preventingsoundtransmission,thereforetheidealsituation
istomakeanenclosureoutofathick,massivematerial.This
hasitsobviousproblems,suchasweight,needingtoopen
theenclosure,andneedingtoprovidewindowstoseein.
Thewindowmaterialwillhavealowmass,increasingthe
soundtransmissionoftheenclosureasanoverallassembly.
Thickerwindowmaterialcanbeused,atanincreasedcost.
Whatisofmostinterestisasubcategoryoftheprincipleof
increasedmass,andthatistheremovalofanygapsor
cracks.Agapisazoneofzeromassandhasamajor
consequenceonsoundtransmission.Ithassuchanimpact
thata1/32"widecrackinthewallofaroomcanallowmore
soundthroughthantheentirerestofthewall.Tocombat
this,theenclosuremustbethoroughlysealed.Thetighterit
is,themoreeffectiveitwillbeatpreventingsound
transmission.
Somehomebuilderswhohaveinstalledafoamliningclaim
animprovement.Smallgainsmaybeseenforacoupleof
unintentionalreasons.Dependingonhowitisattached,it
maybepreventingsurfacesoftheenclosurefromvibrating
andproducingsound.Ineffectitisprovidingsomedamping.
Moreimportantly,itishelpingwiththemassissue.Whileit
providesasmallamountofdirectadditionalmass,itis
coveringupcrucialgaps.Unfortunately,betterresultscould
mostlikelyhavebeenachievedwithasimplerolloftapeor
tubeofsiliconecaulk.
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designalterationsandconstruction
Canchangesbemadetotheplans?
Thefollowingsectionoutlinesdesign
information,andaprincipalreasonfor
includingithereistoprovidesomeknowledge
ofwhythedesignexistsasitdoes,andwhy
someaspectscanandsomecannotbechanged.
Manyoftheotherplansonthemarketmakea
sellingpointoutofstatingthattheycanbe
widelymodifiedtosuitindividualneeds.
Whilethissoundsattractiveinprinciple,there
areseriousproblemswiththisapproach.The
primaryoneisthatchangingthesizeofthe
machinecanhaveseriousnegative
consequencesonitsperformance.Increasinga
dimensioncanincreaseinternalforceson
machinecomponents,aswellasincreasingthe
deflectionofcomponents.Thesestressesand
strainscanbemanytimesinexcessofthewhat
wouldbeencounteredinthemachineasit
existsintheseplans.
Inshort,youshouldnotmakechangestothese
plansunlessyoufullyunderstandwhatthe
consequencesmightbe.Thesizesofall
componentshavebeenoptimizedforthe
overallsizeanduseofthemachine.Proceedto
makechangeswithextremecautionandatyour
ownrisk.
Assemblysteps
Theassemblystepsintheseplansstartwiththe
fabricationofthewoodcomponentsandfinish
withthemetalones.Thissequencewaschosen
becauseitpresentsasmooth,seamlessorderof
constructingthemachine.
However,itishighlysuggestedtoreadthrough
theentiresetofplansandthendecideifthis
sequencemakesthemostsenseforyou.If
thereisanydoubtabouttheskillsinvolvedto
constructthemachine,thenitissuggestedto
fabricatethemetalcomponentsbeforethewood
components.Thissequenceprovidesacouple
ofadvantages:Thefirstisthateventhoughit
maybemoreunfamiliartomanybuilders,metal
canactuallybeeasiertowork.Ithasno
perceptiblegrainandisthereforepredictablein
itsbehavior.Mostofthemetalpartsare
aluminum,whichisasoftmetalandhas
relativelylowcuttingforcesinvolved,muchlike
thoseofahardwood.Thesecondreasonisthat
fabricatingthemetalpartswillconstitutethe
bulkoffabricationtimeandrequirethemost
patiencetomaintainbuildtolerances.The
numberofcuts,holestodrillandtap,and
amountofhandfilingandfinishingwill
ultimatelyendupbeingaconsiderableamount
oftedioustimeconsumingwork.Thissequence
willalsoquicklyrevealthelevelofskillsand
staminatocompletethemetalcomponents.By
thetimeallofthemetalcomponentsare
fabricated,thewoodfabricationwillmostlikely
seemquickandeasy.
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designprocess
Designingamachine:
Thedesignofahomebuiltmachineoftenhasadesign
processthatfollowsthesesteps:
a. Studyexistingdesignsthathavebeenbuiltbyothers.
b. Constructsomethingthatlookssimilar.
c. Bedisappointedwithsomeaspectofitsperformance.
d. (Hopefully)buildasecondone.
Designcanbeaverycomplicatedprocess,requiringnot
onlysignificantknowledgebutgooddecisionmakingskills
tobalancetheoftenconflictingcriteriathatareneedingto
bemet.Progressinanyfieldistypicallyincremental,with
thebreakingofrevolutionarygroundbeingtheexception
ratherthantherule.Therefore,stepsaand'bare
bothinevitableanddesirable.Thequestionbecomes
whatknowledgeandskillsarenecessarytosuccessfully
critiqueandimproveuponexistingdesigns?
DesignProcessandprinciples
Thefollowingisabriefattemptatexplainingthethought
processandrationalebehindthisparticularmachine
design.Thisisprovidedfortworeasons.First,to
perhapsprovideageneralstartingpointandadvicefor
thosewhodecidetodesigntheirownmachine.Secondly,
toprovideafoundationforthosewhomaywishtomake
modificationstotheseplans.Whatfollowsisalistof
pointsofunderstandingthatwereaccumulatedduring
theprocessofdesigningthismachine.Theyrangefrom
observationsoftypicalproblemareas,todesign
philosophy,tostructuralformulasandengineering
information.Tothosewithengineeringknowledge,
pleaseexcuseanyoversimplificationsofconcepts.This
informationisaimedatthosewithlittledesignexpertise
andisnotintendedtotransformanyoneintoacapable
engineerordesigner.Rather,itisintendedtoillustrate
howcomplexitcanbetodesignaseeminglysimpledevice
andhowquicklyonecangetinovertheirhead,even
whenequippedwithalittlebitofoversimplified
information.Designhubrisshouldbekeptincheck,in
favorofthecautiousandprovenpath.
Woodworkingskills
Thismayseemsomewhattangentialtoadesign
process,butitisnot.ManybuildersofaCNC
router,whoareintendingtouseittomillwood,
possessveryrudimentarywoodworkingskills.
Manyhaveneverexperiencedtryingtocontrola
handheldrouter.Itisimportanttohavean
intuitiveunderstandingofthebehaviorofthe
materialthatwillultimatelybemilledwiththeCNC
machine,andhowitinteractswithacuttingtool.A
CNCrouterisaveryadvancedpieceof
woodworkingequipment,andsuccessinusingitis
goingtobemuchgreateriftheoperatorhasasolid
understandingofwoodworkingbasicsandafeelfor
thematerial.Improvingone'swoodworkingskills
willquicklyrevealimportantunderstandingsof
grain,howthetoolwantstofollowit,inwhich
directionsitwantstotear,andwhyitisimportant
tocontrolmachinebacklashsomewayotherthan
throughelectroniccompensation.Theforces
requiredtomoveabladethroughwood,ortohold
itback,maybeunexpected,especiallywhenitis
spinningat25,000rpminarouter.Better
woodworkingskillswillequatetoabetterfeelfor
howtoelectronicallycontrolacuttingtool,andwill
alsoimprovethebuildqualitywhenconstructing
theactualmachine.
Usetheroutertobuildthemachine
IfconstructingaCNCrouter,thenobviouslyatsome
pointarouterwillneedtobepurchasedforuseas
thespindle.Byacquiringitearlyintheprocess,it
canbeusedtofabricatethemachineitself.Many
ofthewoodpartsforthismachinecanjustaseasily
becutwitharouterastheycanacircularsawora
tablesaw.Severalofthecuttingoperations,such
aspockets,willactuallyrequirearouter.Witha
guidefenceandclamps,veryaccuratecutscanbe
achievedwiththehandheldrouter.Usingthe
routerwhilebuildingthemachinewillquicklyreveal
thedifferencesbetweenmovingthetoolleftor
rightalonganedge(climbcuttingvs.conventional
cutting),theimportanceoffeedratesandspindle
speeds,howtoplungeintoaworkpiece,theeffect
ofdifferenttypesofcuttingbits,andthegeneral
forcesinvolved.
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designprocess
Stiffness
Oneofthebiggestshortcomingofmanyhomebuilt
machinedesignsisalackofstiffness,orrigidity.Stiffness
istheabilitytoresistdeflection.Materialshaveelastic
behavior.Atitssimplest,pushingonthemcausesthemto
deflect.Releasetheforceandtheyspringback.Pushtoo
hardanditdoesntspringback.Whenthishappens,ithas
bentorbroken,duetoeitherexceedingthematerial's
elasticlimitandcausingplasticdeformation,orgoing
beyonditsyieldpoint.ALLmachineshavesomeamountof
deflection.AmachinebuiltofHDPEplastichasaverylarge
quantityofitthatmaybeeasilyseenbythenakedeye.
OnebuiltofMDFstillprobablyhasaconsiderableamount,
andisoftenmorethanshouldbeacceptablefor
constructionofamachine.Amachinethatisbuiltof
massivecastironandcostshundredsofthousandsof
dollarsstillhassomedeflection,itisjustinfinitesimally
smallrelativetoitscuttingaccuracy.
Alackofstiffnesscausesseveralproblems.Theobvious
oneisthatifthemachinedeflectsunderacuttingload,
thenthetoolisntinthespotthatthecomputerthinksitis.
Inotherwords,yourcutisnotgoingtobeaccurate.The
otherbigproblemischatter.Amachineisadynamic
structure,meaningthereismotioninvolved.Thatmotion
cancausevibrationsandoscillationsinthemachine
componentsifitcanflexexcessively.Atbest,experiencing
chattermaymeanreducingcuttingspeedortakingcuts
thatarenotasheavy.Atitsworstitcandestroythecutting
tool,thepartbeingcut,orevencausedamagetothe
machine.
Stiffnesscomesfromacombinationofproperties.Thefirst
istheflexibilityofthematerialitself,duetoaproperty
calledModulusofElasticity.Thesecondfactorishowthat
materialisarrangedinspace,duetoapropertycalled
MomentofInertia(ormorecorrectly,theSecondMoment
ofArea.)Thusthefirstfactorisbasedonmaterial
properties,andthesecondongeometricalproperties.
Becausestiffnesscomesfromacombinationofthesetwo
factors,itmeansthattosomeextenthavingasurplusof
onepropertycanmakeupforadeficiencyintheother.
Whatthismeansisthatevenaveryflexiblematerialcan
bearrangedtoproduceastrongandrigidstructure.This
iswhyamachinebuiltofMDFhastobesobulky,asit
needstopositionthematerialinawaythatcan
overcomeitsinherentflexibility.Unfortunatelythisis
stillnotasgoodasusinganinherentlystiffmaterialina
geometricallyefficientway.Soyes,asomewhatrigid
machinecanbebuiltoutofwood.No,neverasrigidas
castiron,norascompact.
Joints
Connectionsbetweencomponentsareasimportantas
materialchoice.Thereisahugedifferenceinthe
amountofforcethatcanbetransmittedthrough
differenttypesofjoints.Onebiglimitationinusing
woodforanystructuralapplication,whetheramachine,
abuilding,orapieceoffurniture,isdesigningadequate
jointdetails.Subtledifferencesinhowpiecescome
togethercanhaveasignificanteffectonstrength.
CreatingstrongjointsinamaterialsuchasMDFisno
smallundertaking,butitcanbedone.
Basicstructuraldesignprinciples
Someunderstandingofverybasicstructuralprinciples
willgoalongwayindesigningamachine.Afewsimple
experimentscanhelpillustratethem.Attemptingto
twistacardboardboxwithnotopisrelativelyeasy.
Tapingatopinplacesothatallsixsidesaresolid
planesmakesitmanytimesmoreresistanttobeing
twisted.Thishasincreasedthetorsionalstrengthofthe
assembly.Attemptingtoflexarulerthatislyingflatand
spanningbetweentwosupportsisalsorelativelyeasy.
Repeatingthiswiththerulerstandingonitsedgeshows
noperceptibledeflection.Thishasincreasedthe
bendingstrengthofthemember.Attemptingtoholda
pieceofthinpaperstraightout,whileholdingatonly
oneedge,anditwilldroopdown.Puttinga90degree
crease,oracurve,inthepaperthatisperpendicularto
theedgebeingheld,anditwillnowrigidlycantilever
out.Thischangeingeometryhasmadeitintoaform
resistantstructure.
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designprocess
Buildingamodel
Itiscommontobuildavirtual3dmodelofapotentialdesign,
withsoftwaresuchasSketchUp,Rhino3d,Solidworks,etc.
However,oneofthebigproblemsthatcomeswiththeeasy
availabilityof3dmodelingsoftwareisthatitdoesnotgive
anysenseofmaterialityandrealworldbehavior.Every
designworksperfectlyonthecomputerscreen.Theresult
beingthatendlessvariationsofadesignaredrawnwithouta
realunderstandingofitsbasicshortcomings,andfew
improvementsaremadefromoneiterationtothenext.
BeforededicatingsignificanttimetoconstructingaCNC
machine,itcanbeveryvaluabletoevaluatethedesignby
constructingasmallscalephysicalmodel.Inadditionto
revealingpotentialproblemswithoverallconstructabilityor
interferenceofparts,itcangiveasenseofitsstructural
performance.Bybuildingitoutofamaterialthathassome
inherentflexibility,itwillbeeasytowitnesshowthe
geometryofthedesigneffectsthestiffness.Materialssuch
as1/16chipboard(materialthatcerealboxesaremade
from,canbesourcedatagoodartsupplystore,)matboard,
posterboard,orbristolboardareexcellentforthispurpose.
Avoidstiffmaterialslikefoamcore.Themoreflexiblethe
material,theeasiertoseeanexaggerationofwherethe
designwillflex.Amodeldoesnotneedtobeconstructedso
thatpartsslideormove,itcanbefixedinmidtravel.
However,itshouldbeconstructedinamannerthatmimics
howthematerialwillreallycometogetheratjoints,asthis
canbeasignificantlocationofflex.
Amodelbuiltasjustdescribedcanbepushed,twisted,and
flexedtoseewherethedesignlacksstiffness.Ifitseems
excessivelyflexible,makingmodificationstothephysical
model,orconstructinganewversion,canbeaquickwayof
makingsignificantadvancesinimprovingthedesign.This
methodwilloftenrevealareasofweaknessthatwerenot
anticipated,andthiswillbehappeningduringaphasewhere
theyareeasilycorrected.Onceanactualmachineis
constructed,makingstructuralchangesmaybenearly
impossible.Attemptingtopushaphysicalmodeltothepoint
ofbreakingcanalsobeinstructive.Ifittakessignificant
force,andfeelslikeitdoesnotflexatallbefore
catastrophicallyexploding,itisagoodindicatoroftheoverall
stiffnessoftheassembly.Ifitsoftlycrumples,oreasily
comesapartattheseams,moredesignworkisprobably
required.Itispossibletobuildaposterboardmodelthatis
nearlyimpossibletobreakinyourhands.
Matchedlevelofcomponents
AcommonproblemwithDIYmachinedesignisthenecessity
ofspecifyingindividualcomponentsthatworkwellin
conjunctionwitheachother.Amachineshouldhavea
consistentlevelofaccuracy,orratherofinaccuracy,inits
componentsthroughout.Ascenariolikeinstallingexpensive
highaccuracyballscrewsformotioncontrolonanMDF
machinewillneverrealizethebenefitofthehighquality
components.TheamountofflexintheMDFmaterial,orits
dimensionalinstabilityduetomoistureintheatmosphere,
willfarexceedthetolerancesthattheballscrewscanattain.
Thelevelsofaccuracybetweenthetwocomponentsmaybe
offbyordersormagnitude.Thequalitylevelofall
componentsneedstoimprovetogetherinordertosee
improvementsinoverallaccuracyofthesystem,otherwise
moneyismerelybeingwasted.
Hereisabasiclistofaspectsthatshouldhavesomewhat
closelymatchedaccuracylevels:
Framematerial.
Rigidityofframedesign(NOTthesameasframematerial)
Abilitytoalignandadjustthemachine.
Typeofbearingsorguides.
Methodofdrivingmotion.
Backlash,ortheamountofplayinthemachine.
Electronicresolutionofsteppersorservos.
Machinespeed.
Spindlepower.
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designprocess
Toleranceandaccumulationoferror
Beyondcreatingarigidmachinethatwillnotdeflectundera
load,thereareotherfactorsindesign.Oneistheissueof
tolerance.Manyhomebuiltmachinedesignsmakeclaims
like:cutsaccurateto.000025".Anumberlikethisis
merelyatheoreticalelectronicresolutionofthestepper
motors,andhasnobearingonactualaccuracyoftheoverall
machine.Itinnowaytranslatestoaccuracyatthetipofthe
tool,whichiswhereitcounts.Whatdoeseffectaccuracyis
theindividualtolerancesofthevariouspartsofthemachine
workingtogether.Sometimesinaccuracieswill
serendipitouslycanceleachotherout,asaninaccuracyin
onedirectionwillbecounteractedbyaninaccuracyinthe
otherdirection,thenetresultbeingthattheerrorisnot
large.Butthisisanuncommonsituation,andtheindividual
errorsaremorelikelytoaccumulateandaddtoeachother.
Soatheoreticalaccuracytoleranceforthemachineisbest
arrivedatbyaddingallofthepossiblecausesofinaccuracy
toarriveatatotalpossibleinaccuracynumber.Herearea
fewthingsthatcontribute:
Themachineflexing:frame,motormounts,etc.
Play:spacebetweenbearingsandrails.
Linearmotioninaccuracy:railsnotstraight,
variationindimension,notparallelorinplane.
Lineardriveinaccuracy.
Electronicserror.
Degreesofconstraint
OnecommonprobleminmanyDIYdesignsishavingthe
machinebindunderacuttingload.Eachaxisofthe
machineneedstosmoothlyrollonabearingsystem,and
eachaxisneedstohavebearingsconfiguredinawaythat
willconstrainthemotionsothatitwillonlygoexactlyinthe
directionofthataxis.Thistypicallyrequiresmanybearings
thatarespreadsomewhatfarapart.Allworkswellwiththis
arrangementuntilforcesonthemachinecauseflexing,and
somecomponentsarenolongerinexactalignmentwiththe
directionoftravel,causingbinding.Thearrangementof
bearingsontheYaxisofthedesigninthismanualare
somewhatunconventional.Theyarearrangedsothatthe
rightsideofthegantryisfullyconstrainedagainstrotation
intwodirections.Thegantryineffectisthencantilevered
outfromthissetofbearings.Thebearingsontheleftside
ofthegantryactasoutriggersthatstabilizeitsposition.The
bearingconfigurationontheleftisnotfullyconstrainedin
itself,butprovideconstrainttotheoverallsysteminthe
thirddirectionofrotation.
Removingonedirectionofconstraintfromtheleftis
intentional.Ithasbeendonethiswaysothatthemachine
cannotbindifthereisexcessiveflexingofthegantry.
Flexingofthegantrywillallowasmallrotationinone
directiontoabsorbthisforce.Whileundertheseconditions
theremaybesomeinaccuracyinthecutduetodeflection
ofthegantry,themachinewillkeepmovingandnotbind.
Acceptingthisveryminorinaccuracywasfelttobeabetter
situationthanhavingthemachinebind,whichmostlikely
wouldresultinacompletelyunusablepart.Whena
machinewithsteppermotorsbinds,whatcanoftenhappen
isthatthecomputerkeepsfeedingthesignaltothemotors
becauseitdoesnotknowthatthereisaproblem.Ifthe
machinesuddenlystartstomoveagain,itisnowreceiving
codethatisoutofsyncwithwhereinthecuttingprocessit
leftoff.Theresultisalargecuttingerror.Donotadd
additionalbearingstotheleftsideofthemachineunless
youunderstandtheimplicationsfordoingso.Itwillrequire
muchmoreaccuratealignmentofthemachinetoprevent
binding.
Alignment.
Aligningatypicalhomebuiltmachinecanbeproblematic.
Smoothbindfreeoperationrequiresaccuratealignment
betweenbearingsurfacesoneachaxis.Itrequiresgetting
themachineparallel,square,andinplane.Thiscanbea
verydifficulttasktoaccomplish.Nearlyallhomebuilt
machinesprovidesomemeansofprovidingadjustability,
however,manyusemethodsthatmakefineadjustment
verydifficultorimpossible.Somedonotprovideenough
directionsofadjustability.Thebiggestproblemisthat
nearlynoneofthemprovideanysortofreferenceplaneto
measurefrom.Itdoesnogoodifthemachinecan
theoreticallybealigned,butthereisnopracticalwayof
makingmeasurementstofindthatalignment.Thisdesign
attemptstosolvetheseproblemsinseveralways.Using
themanufacturedfacesofstockmetalpiecesprovides
someamountofautomaticalignmentbetweenparts.Allof
thebearingshaveasetscrewtoallowveryfine
adjustmentsoftheirpreloadagainsttheaxisrailsthatthey
ridealong.Finally,bypouringathinselflevelinglayerofa
verylowviscosityepoxyonthebedofthemachine,itcan
beusedasaconsistentreferenceplanefromwhichtobase
allalignments.
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structuraldesign
Structuraldesign
Rigidity:
Forthedesignofthemachineintheseplans,rigidity
becametheprimarydesignfactor,aseverythingsprings
fromthestiffnessofthemachine.Accuracygoeshandin
handwithflexibility.Itdoesnotmatterifyourelectronics
cancontrolmotionto.0001"ifyourmachineframeflexes
1/8"underacuttingload.Thisseemedtobethebiggest
downfalloftheexistinghomebuiltdesigns.Many
machineswerebeingbuiltprimarilyofMDF(medium
densityfiberboard.)Thismaterialisbynaturevery
flexible.Themannerinwhichitwasbeingarrangedoften
didnothelpthesituation.
Asmentionedearlier,therearetwofactorsatplayto
achievestiffness.Oneisapropertycalledmodulusof
elasticity.Thisapropertyofthematerialandis
essentiallyameasureofitsflexibility.Ahighernumber
indicatesastiffermaterial.Astiffermaterialisobviously
desirablewhenbuildingamachine.Thesecondfactorat
playismomentofinertia.Thisisameasureofstiffnessof
ashapeorgeometricalarrangementofthematerialin
space.Thesameamountofamaterialcanbeusedwith
differingamountsofefficiency.Anexamplewasgiven
earlierofthebendingefficiencyofaruler,comparingit
whensupportedonitsflatsidevs.whenonitsthinedge.
Thisphenomenonishappeningduetothemomentof
inertiaoftherulerbeinggreaterinonedirectionthanthe
other.Anotherexamplewouldbetoflexathinsteelrod.
Asteelrodthatisabout1/4"indiametercaneasilybe
flexedandbentbyhand.However,thatsamequantityof
materialcanbemadeintoalargediameterhollowtube
withathinwallthickness.Thistubewouldnotbeableto
beflexedbyhand.Bothhavethesameamountof
material,butthetubehasamuchhighermomentof
inertia.
Togetanideaoftherangeofmaterialstiffness,hereisa
modulusofelasticitychart.Allvaluesareinpsi:
Rubber 1,50015,000
Lowdensitypolyethylene 30,000
HDPE 200,000
Polypropylene 217,000290,000
Nylon 290,000580,000
MDF(woodcomposite) 530,000
Oakwood(alonggrain) 1,600,000
Pinewood(alonggrain) 1,300,000
Magnesiummetal(Mg) 6,500,000
Aluminiumalloy 10,000,000
Brassandbronze 17,000,000
Titanium(Ti) 15,000,00017,500,000
Copper(Cu) 16,000,00019,000,000
Wroughtironandsteel 30,000,000
Lookingatthischart,theinherentproblemsofusing
materialslikeplasticorMDFformachineconstruction
becomeimmediatelyapparent.Theyareordersof
magnitudemoreflexiblethaneventhelowestmodulus
metals.Thephilosophyinthedesignofthismachine
wastousematerialsofhighmoduluswhereverpossible.
Onecounterintuitiveoutcomeofthisisthatitisoften
actuallylessexpensivetousesmallquantitiesofhigher
modulusmaterialsthanlargequantitiesoflowmodulus
materials.Designingusinghighermodulusmaterialsalso
allowsthemachinetobemorecompact,whichcan
furtherhelpinreducingflex.
Itisimportanttounderstandthattheabilityfora
materialtoresistdeflectionisnotexactlythesameasits
strength.Thesearetwoseparatemeasuresof
materialproperties.Forourpurposes,theabilityto
resistdeflectioniswhatismoreimportant.Ifthereis
enoughmaterialtoprovideastiffenoughdesign,thereis
verylittlechanceofitnotbeingstrongenough,sowe
canignorethatstructuralneed.
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structuraldesign
MomentofInertia
Asbrieflydiscussedonthepreviouspage,thesecondfactorin
achievingstiffnessishowthematerialisdistributedinspace.
Thisiscalledmomentofinertia,ormorecorrectly,thesecond
momentofarea.Asalsomentioned,sincemostdesignsare
drivenbystiffnessrequirementsratherthanstrengthneeds
(theconcepthereisthatifyoubuiltitsothatitisstiffenough,
itisgoingtoautomaticallybestrongenough)thefocushere
willbeonstiffness.Unfortunately,comparingthemomentof
inertiaofevenverybasicdesignoptionsagainsteachother
requiressomemath.Afewsimpleequationswillbeintroduced
here.Hopefullythiswillprovidesome(relatively)easy
informationtoseetheimplicationsofalternatedesign
decisions.Theseformulaswillhelpcomparescenariossuchas
increasingthedimensionsofmember,comparingsolidshapes
tohollowsections,andhowmuchdeflectionincreasesifaspan
isincreased.
Tofindsolutionstothesequestions,twotypesofinformation
arerequired.Firstisthemodulusofelasticity,whichisa
propertyofthematerial.Thesecondisthemomentofinertia
whichisapropertyofthecrosssectionalshapeofthepart.
Thisinformationworksincombinationwithotherfactorssuch
astheoveralllengthofthepart,howaloadisapplied,and
howitsendsaresupported.
Example:
Asimplepieceofmetalbarstockthathaseachend
restingonasupport.Asingleloadispressingdownin
thecenterofit.Whatfactorsmakeitflexibleorstiff?
Sectiondimensions.Increasingitssizeinsectionwill
makeitstiffer.A1"x1"barwillbestifferthana"x"
bar.
Sectionshape.Makingthebartallerwillmakeamuch
biggerdifferenceinmakingitstiffthanwillmakingit
wider.(Thinkbacktotherulerexample).Anothergood
exampleofthisisafloorjoist.A2x12floorjoistisgoing
tobestifferthana2x6floorjoist.
Length.Alongerpieceisgoingtobemoreflexiblethana
shortone.
Endconstraints.Thebarinthisexampleisjustresting
onasupportateachend.Thismeansitcanrotate
slightlyasthebardeflects.Ifthebarwasheldrigidlyat
eachend,likeifitwasweldedsolidlytoanotherobject,it
wouldmakeitmoreresistanttoflexing.
Load.Aloadthatisspreadoutoverthelengthofa
memberwillcauselessflexingthanifitisall
concentratedatthemidpoint.
Thecalculationofdeflectionisathreestepprocess:
1. Lookupthematerial'smodulusofelasticityinachart.
2. Calculatethesectionmodulusbasedoncrosssection
shape.
3. Calculatethedeflection.Thedeflectionformulastake
manyofthefactorssuchasendconstraintsandloading
conditionsintoaccount,soitisjustamatteroffinding
theformulathatmatchesthesituation.
2 1 3
Calculatemomentofinertia Findmodulusofelasticity Calculatedeflection
a
a
b
d
a a
a
a
b
d
d
D
I =
a
12
4
crosssectional
shape
formula
I =
bd
12
3
I =
a
12
4
b
b
I =
a
12
4
b
4
I =
bd
12
3
hk
3
k
h
I = d 0.049
4
d
I = d 0.049
4
D
4
( )
I = E =
L
W
=
W L
48 E I
3
L
W
=
W L
192 E I
3
max. deflection =
L
W
=
W L
3 E I
3
simplysupportedatbothends,
forceappliedatcenterofspan.
fixedsupportatbothends,
forceappliedatcenterofspan.
fixedsupportatoneend,
forceappliedendofcantilever.
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structuraldesignformulas
LDPE 30,000
HDPE 200,000
Polypropylene 217,000290,000
Nylon 290,000580,000
MDF 530,000
Oakwood 1,600,000
Pinewood 1,300,000
Magnesium 6,500,000
Aluminium 10,000,000
Brass&bronze 17,000,000
Titanium 15,000,00017,500,000
Copper 16,000,00019,000,000
Wroughtiron 30,000,000
Steel 30,000,000
Units:
Alldimensionsonthispageareininches.
ModulusofElasticityunitsareinlb/in
2
0.5
0.5
I =
a
12
4
L
W
=
W L
48 E I
3
I =
0.5
12
4
I =0.00520833
AluminumE=10,000,000
1
2
3
=
(10) 24
(48) (10,000,000) (0.00520833)
3
=
138,240
2,499,998
=
0.055" deflection
Example:
-simply supported at ends
-force applied at center
1/2" square aluminum
W= 10 lb at center
L= 24" long
step
step
step
Now, lets change the material
to 1" square aluminum.
All else stays the same.
1.0
1.0
I =
a
12
4
L
W
=
W L
48 E I
3
I =
1.0
12
4
I =0.0833
=
(10) 24
(48) (10,000,000) (0.0833)
3
=
138,240
39,994,000
=
0.003" deflection
Notethattheoriginal
examplehadover17
timesasmuchdeflection
asthesecond!
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deflectionexample
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structuraldesignconclusion
structuraldesignconclusion
Thesecalculationsonthepreviouspagesareadequate
forverybasiccrosssectionalshapesandsimpleloading
situations.Essentiallytheyareforfindingdeflectionin
simpletypesofbeams.Unfortunately,therealworldis
rarelythatcooperative.Assoonasthecrosssection
becomesmorecomplex(likeanIbeamforexample,)or
multiplepiecesareattachedtogether(likethegantryon
thisdesign,)calculationsbecomemuchmore
complicated.Determiningthedeflectioninthese
compositeassembliesisbeyondthescopeofthissimple
demonstration.Similarly,anyintroductionofloadsother
thantheveryidealizedconditionsshownintheformula
diagramsalsomakescalculationtremendouslymore
complicatedandisbeyondourscope.
Notonlydocrosssectionpropertiescomplicatethe
calculations,buttherearecomplexitiesevenwithin
whatmayseemtobeanadequatesolutionaccordingto
thesecalculations.Forexample,increasingthesizeofa
hollowsectionwhilereducingitswallthicknesswillresult
inastiffermember.However,therearelimitstothis.
Wallthicknesscannotbereducedtoofarorthemember
willbevulnerabletobucklingunderaload.Sowhilethe
basicdeflectionscalculationsshowittobeadequate,
thereareotherfactorsthatmayrejectthisasasolution.
Amongthoseotherfactors,itisunusual,indeeddifficult,
foranyparttobedesignedsothatthereisonlyonetype
ofstressinvolved.Agoodexampleofthiswouldbea
truss,whichoperatesontheprinciplethatitsmembers
areeitherinpurecompressionorpuretension.In
practicethisisverydifficulttoachieveandthereis
nearlyalwayssomeamountofbendingforceintroduced
duetotherealitiesofjointdesign.
InthecaseofaCNCmachinesuchasthisone,thegantry
experiencesacombinationoftorsionanddeflection
forces.Notonlydothecuttingforcespushonitcausing
ittodeflect,butthoseforcesarenotaligneddirectly
withitscenterline.Thecuttingforcesarecantilevered
somedistancedowntheZaxis.Thiseccentricloading
introducesatorsionaltwistintothegantry.
Understandingandcalculatingcombinationsofforces
canbeverycomplexandiswellbeyondtheaverage
homebuilder'sanalyticalabilities.Itisimportantto
keepinmindthatthisisnearlyalwaystherulerather
thantheexception,sothestructuralcalculationsshown
hereshouldbeviewedasaguidelineforunderstanding
someverybasicprinciples.Itcanbeusedasarough
meansofcomparingtheeffectsofchangingsizesof
members.Thisshouldinnowaybeseenasadefinitive
guideforstructuraldesign,ifanythingitshouldbe
takenasanillustrationofjusthowdifficultitcanbeto
understandevensimpleloadsonapart.
Asuccessfuldesignalsodependsoncreatingjointsthat
cantransmitloadsbetweenpartsinaneffectiveand
appropriateway.Thisisoneotheraspectthatthese
simplecalculationsdonotconsider.Alsokeepinmind
thatallofthisinformationpertainstostaticconditions.
Rememberthatamachinetoolisadynamiccondition
andmakesitmuchmorecomplextopredictits
structuralbehavior.Kineticmovementsandrotating
partscanintroducemomentum,vibrations,and
oscillationsthatcanamplifystaticstressestothepoint
ofbreakingfailure.Discussionofdynamicbehavioris
wellbeyondthescopeofthissetmanual.
Asstatedearlier,theintentofprovidingthis
informationistwofold.First,itisheretoillustratethat
whatmayseemsimplecanbequitecomplexto
calculateandpredict.Pleasebearthatinmindwhen
temptedtomakechangestotheplans.Thesecond
reasonforprovidingthisknowledgeisthatitcangiveat
leastsomesenseoftheimplicationsofmakingchanges.
Itisquiteeasytodoafewcalculationsandseethat
doublingthelengthofpartmakesitmuchmoreflexible.
Todirectlyseethosenumbersandbeabletocompare
themmayjustaidinyourjudgmentofhowfar
dimensionscandeviatefromthoseintheplansbefore
thecrosssectionalsizeofamemberneedstochange.
Intheidealsituation,thisknowledgemighthelpyou
improveuponthedesignasgiven
Namingconventionsfor
axesanddirectionsfollow
thesestandards
throughout:
X
Y
Z
front
rear
right
left
GENERALNOTES
Donotmeasureoffofprinteddrawings.Usedimensionsas
indiactedondrawings.Scaleisnotindicatedondrawings
duetovariationinprinteraccuracy.Printingat100%scale
factormaynotguaranteeexactly100%onpaper!
Donotmakechangestothedesignwithouthavingafull
understandingoftheirimplications.Thismachinewas
carefullydesignedsuchthatallcomponentsworktogether
asaintegratedwhole.Changesmayhaveunforeseen
implicationslaterinthebuildprocess,ormaynegatively
affecttheoperationofthefinishedmachine.
DimensionsonmechanicalpartsaregiveninImperial
decimalunits.Dimensionsaregiventoeither2decimal
placeaccuracyormaybegivenasfulldecimalequivalents
tofractions.Thisdoesnotindicatedegreeoftolerance
required.
Tolerances.Anaccuracyof+/1/32"isgenerallysufficient
onmetalparts.Anyexceptionstothiswillbenoted.Cut
woodpartsshouldaimforthissamelevelofprecision.
Counterbores.Manymetalpartsindicatecounterbores.
TheseareOPTIONAL.Counterboresarepresenttoreduce
thethicknessofmaterialtobetapped,tomakehand
tappingeasier.
Filingtofit.Iftolerancesarenotheldaccuratelyenoughit
maybenecessarytofilesomepartsslightlyduring
assembly.
BESAFE.Usegoodjudgmentwhileworkinganddonot
attemptanythingthatisbeyondyourabilityorthatmay
jeopardizeyourpersonalsafety.
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generalbuildnotes
METAL
1018
coldrolled
rectangular
bar
A36
hotrolled
angle
6063T52
rectangular
tube
(1)@24.00" 24.00total
6061T6
squarebar
(2)@.75
(2)@1.25
(1)@2.50
(1)@6.75
(1)@7.25
(4)@7.375
(1)@8.50
(1)@10.75
(1)@20.75
96.00total
6061T6
rectangular
bar
(1)@5.625 6.00total
.75"x.75"bar
1.50"x3.00"x.125"wall
.125"x.75"bar
A
L
U
M
I
N
U
M
(1)@4.25
(misc)4.5"
9.00total
.1875"x2.50"bar
(2)@24.00" 48.00total
.1875"x3.00"bar
(1)@.75
(1)@1.00
(1)@1.25
(1)@1.875
(1)@2.50
8.00total
.375"x1.25"bar
(4)@1.75
(2)@2.75
(1)@5.625
(1)@11.25
31.00total
.75"x1.00"bar
(1)@2.00"
(2)@2.25
(1)@6.75
(2)@4.25"
22.50total
.75"x1.25"bar
(2)@4.25 9.00total
.75"x1.75"bar
(2)@24.00" 48.00total
(2)@24.00" 48.00total
1.25"x1.25"x.125"angle
.25"x1.50"CRSbar
S
T
E
E
L
(1)@12.00
(1)@22.50
36.00total
.25"x2.50"CRSbar
NOTE:
Totalquantityforeachsizeofstockislisted.
Totalquantitiestypicallyincludeadditionalmateriallengthtoinclude
widthofsawcuts.Thesequantitiescanbeusedwhenordering
materialinbulklengths.Iforderinginbulklengths,notethatitis
oftenlessexpensivetoroundquantitiesuptothenearestwholefoot.
Withineachsizeofstock,individualpartlengthsarealsolisted.These
quantitiescanbeusediforderingmaterialbyindividualpartlength.If
orderingbyindividualpartlength,notethatmostsupplierswillonly
guaranteecutaccuracyto+/1/16",andcutsmaynotbeperfectly
squareorhavehighfinishquality.
NOTE:
Beforeorderingmetalorotherparts,consulttheADDENDUMon
page171ofthismanual.Itoutlinesupgradingthemachinewith
thrustbearingsontheZaxis(HIGHLYRECOMMENDED.)
Aseparatebillofmaterialsislistedforthesepartsintheaddendum.
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billofmaterials1
(46)sealedrollerbearings,ABEC7skate8mmx22mmx7mm(608size)
MOTION
400XLtimingbelt200teethx3/8"width,McMasterpart#6484K445
500XLtimingbelt250teethx3/8"width,McMasterpart#6484K451
OR
10feet3/8"widex.200XLpitchopenendedtimingbelting.
(12')steppermotorwire,cont.flex,shielded,McMasterpart#7673K44.
Limitswitchwire.
(5)limitswitches,SPDTsubminileverswitch,RadioShackpart#275016(orsimilar).
Emergencystopswitch.
8"3/810acmeonestartprecisionrod,McMasterpart#99030A327(36"length)
(1)delrinantibacklashnutw/.925"squareflange,DumpsterCNCpart#AC38101LN
(1)delrinshaftcoupler,@steppershaftdia.,DumpsterCNCpart#AC38101AC
OR
8"3/88acmetwostartprecisionrod,McMasterpart#99030A315(36"length)
(1)delrinantibacklashnutw/.925"squareflange,DumpsterCNCpart#AC38082LN
(1)delrinshaftcoupler,@steppershaftdia.,DumpsterCNCpart#AC38082AC
OR
8"3/88acmefourstartprecisionrod,McMasterpart#99030A303(36"length)
(1)delrinantibacklashnutw/.925"squareflange,DumpsterCNCpart#AC38084LN
(1)delrinshaftcoupler,@steppershaftdia.,DumpsterCNCpart#AC38084AC
(2)10toothtimingpulleys,3/8"wide,.200XLpitch,boredia.tomatchstepper
motorshafts
ELECTRICAL
woodfiller.
carpenterswoodglue.
paintandprimer.
24fluidoz.(32fluidoz.recommended)lowviscosityepoxyresin&hardener,
<600cpsviscosity.
30"pianohinge.
(2)11/2"utitlityhinges.
(2)2"utilityhinges.
(2)magneticdoorlatches.
cableties.
MISC.
PLYWOOD
PLASTIC
(2)4'x8'sheets,3/4"sandedfinishplywood,suchas
cabinetgrade.
Noteonplywood:
While"cabinetgrade"isspecified,theimportantqualitiesto
lookforinplywoodisthatithasasandedfinishonboth
faces,preferablyahighcountofcoreplies,andcoreplies
withnovoids.
Nominal3/4"plywoodisoftenmarkedandmeasures23/32".
Thisthickness,orcloseequivalentmetricsizes,willnot
affecttheconstructionofthemachinebase.Tothegreatest
extendpossible,thedesignallowsforsuchsmallvariationin
materialthickness.
(1)24"'x24"'sheet,polycarbonate.
~1/8"min.thickness,~3/16"preferred.
Min.recommendedsteppermotorsize:275oz./in.
Steppermotorchoicemaydependonthetypeofmaterials
thatyouintendtocutwiththemachine.Forverysoft
materials,suchasfoam,themachinemayperformadequately
withsteppermotorswithalowerratingthanthesuggested275
oz./in.
Steppermotors,motordrive,andpowersupplymustallbe
carefullymatchedtoeachotherforpropermotor
performance.Informationonmakingthesedecisionsis
beyondthescopeofthismanual.Forthisreason,itis
suggestedthatmotors,drive(s),andpowersupplybepurchased
asaprepackagedkitfromareputablesource.
ELECTRONICS
HARDWARE
hexheadbolts
(1) #1032x.75(or5mmx20mm)
(14) 1/420x.5bolts(modified,seepage86)
(28) 5/1618x1.5(8modified,seepage86)
(1) 5/1618x2.5
socketheadcapscrews
(2) #1032x.75
(7) 1/420x1/2
(1) 5/1618x2.5
(4) 5/1618x3
soc.headcapscrews(ORmachinescrews)
(4) #440x1
(8) #1032x1
(4) #1032x2.5"
lagbolts
(30) 1/4x1.25
nyloninsertlocknut
(4) #440
(8) #1032
(48) 1/420
(35) 5/1618
flatwashers(SAE)
(4) #4
(20) #10
(100)1/4
(100)5/16
(6) 3/8"(modified,seepage86)
lockwashers
(4) #4
(12) #10
(28) 1/4
soc.headcapscrews(ORhexbolts)
(1) 1/420x1
(1) 5/1618x2
fenderwashers
(2) 5/16
grade8hardware
(4) 5/1618x3bolts
(8) 5/16washers
(4) 5/16lockwashers
(4) 5/1618hexnuts
setscrews(grubscrews)
(50) #1032x3/8"
(2) #1032x3/4"
HARDWARE
rollpins
(4) 3/16"x2"
threadedrod(allthread)
(96")1/420(totallength)
nails
(1lb) 6dbrightfinish
woodscrews
(1lb.box)#10x1.25"
(1lb.box)#10x3"
Acmerodchoiceisacompromisebetweenspeedandresolution.Singlestartwill
haveafinerresolution,butslowtravelspeed.Fourstartwillmovequicklywith
slightlylessresolution.Ingeneral,thetwoorfourstartwillstillhaveenough
resolutionformostneeds,andisthusrecommended(fourstartpreferred).
Also,lowtorquesteppermotors(below300oz/in)mayrequiresinglestartor
doublestart,foradditionalmechanicaladvantage.
NOTE:
ConsultADDENDUM(page171)foradditionalZaxisthrust
bearingpartsthatarenotlistedinthisbillofmaterials.
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billofmaterials2
FABRICATEDMETALPARTS
part# partname #reqd.
01 gantrybottom 2
02 gantrytube 1
03 gantrylefttop 1
04 gantryrighttop 1
05 gantryspacer 1
06 gantryouterright 1
07 Ymotormountfront 1
08 Ymotormountrear 1
09 Xbeltplate 1
10 Xbeltclamp 1
11 Yrail 1
12 carriageblockrearupper 1
13 carriageblockrearlower 1
14 bearingblock 3
15 bearingblock tapped 1
16 carriageblockfrontright 1
17 carriageblockfrontleft 1
18 spacerupper 2
19 spacerlower 2
20 Zmotormountright 1
21 Zmotormountleft 1
22 Zcableplate 1
23 Ybeltclamp 1
24 Zrail 1
25 Zrailblock 1
26 nutplateblock 1
27 nutplate 1
28 Xrail 2
29 Xrailangleleft 1
30 Xrailangleright 1
31 Xplateright 1
32 Xplateleft 1
33 Xbeltpulleyadjuster 1
34 cablearm1 1
35 cablearm2 1
36 cablearmmountingblock 1
37 routermountRidgidR2401 2
38 routerclampRidgidR2401 2
39 routermountBoschColttop 1
40 routermountBoschColtbott. 1
41 routerclampBoschColttop 1
42 routerclampBoschColtbott. 1
43 Xlimitswitchbracket 2
44 Ylimitswitchbracket 2
45 Zlimitswitchbracket 1
G
A
N
T
R
Y
C
A
R
R
I
A
G
E
Z

A
X
I
S
X

R
A
I
L
S
FABRICATEDWOODENPARTS
part# partname #reqd.
A bottomskin 1
B Yrib1 2
C Yrib2 2
D Xrib1 2
E Xrib2 5
F topskin 1
G wallplate 3
H verticalrib 6
I rightwallplate 1
J righttopplate 1
K lefttopplate 1
L leftskin 1
M rearplate 1
N rearplatedoor 1
O leftinnerskin 1
P rightinnerskin 1
Q rightskin 1
R frontplate 1
B
A
S
E

A
S
S
E
M
B
L
Y
C
O
V
E
R
STUDSCHEDULE
part# length #reqd.
SA 1.25" 5
SB 1.5" 1
SC 1.75" 12
SD 2.25" 2
SE 2.5" 2
SF 2.75" 3
SG 3.25" 4
SH 3.50" 2
SI 8.00" 1
LISTOFFABRICATEDPARTS
MODIFIEDHARDWARE
part# partname #reqd.
H1 thinheadbolt 8
H2 shortenedbolt 14
W1 enlargedwasher 6
S coverfront 1
T covertop 1
U coverside 2
V coversidefiller 2
W coverrear 1
R
O
U
T
E
R
ROUTERSTUDS
part# length #reqd. Model
RSA 2.75" 4 RidgidR2401
RSB 3.00" 4 BoschColt
(1/420studs)
(1/420studs)
FABRICATEDPLASTICPARTS
part# partname #reqd.
P1 coverwindowfront 1
P2 coverwindowtop 1
P3 coverwindowside 2 C
O
V
E
R
NOTE:
ConsultADDENDUM(page171)foradditional
fabricatedpartsthatarenotlistedhere.(foraddition
ofZaxisthrustbearing)
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FabricatedPartslist
01gantrybottom
studSG(3.25")
02gantrytube
03gantrylefttop
11Yrail
studSH(3.50")
studSC(1.75")
01gantrybottom
04gantryrighttop
05gantryspacer
06gantryouterright
09Xbeltplate
10Xbeltclamp
08Ymotormountrear
studSA(1.25")
studSD(2.25")
07Ymotormountfront
5/1618x2.5"bolt.
studSG(3.25")
(7)1/420x.5"socketheadcapscrews.
1/420x1"bolt
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30
explodedgantry
15bearingblocktapped
studSC(1.75")
13carriageblockrearlower
14bearingblock
studSC(1.75")
20Zmotormountright
21Zmotormountleft
16carriageblockfrontright
14bearingblock
studSC(1.75")
14bearingblock
studSC(1.75")
17carriageblockfrontleft
18spacerupper
23Ybeltclamp
studSA(1.25")
studSE(2.50")
22Zcableplate
studSG(3.25")
19spacerlower
12carriageblockrearupper
(4)5/1618x3"
grade8bolts.
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31
explodedcarriage
Locationsofallbearingsindicatedinred.
Lookclosely,someareobscuredbyother
parts.Thereareatotalof38bearingsin
thisillustration,includingthetwothatare
usedasabeltpulley.
AllbearingsaresealedABEC7skate
bearings,8mmx22mmx7mm.
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32
bearinglocations
24Zrail
25Zrailblock
26nutplateblock
27nutplate
studSB(1.50")
studSF(2.75")
38routerclampRIDGID
37routermountRIDGID
studSC(1.75")
studSA(1.25")
RIDGID
R2401
BOSCH
COLT
studRSB(3.00")
studRSA(2.75")
39routermountBOSCHtop
40routermountBOSCHbottom
41routerclampBOSCHtop
42routerclampBOSCHbottom
studSH(3.50")
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33
explodedZaxis
31Xplateright
29Xrailangleleft
28Xrail
28Xrail
30Xrailangleright
33Xbeltpulleyadjuster
32Xplateleft
5/1618x2.5"socketheadcapscrew.
5/1618x2.00"bolt.
#1032x.75"hexheadmachinescrew.(or5mmx.8)
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explodedXrails
34cablearm1
35cablearm2
36cablearm
mountingblock
studSF(2.75")
studSF(2.75")
studSI(8.00)
shortenasrequiredfor
cablemanagement.
washerW1
washerW1
washerW1
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35
explodedcablearms
Ftopskin
DXrib1
DXrib1
EXrib2
Abottomskin
BYrib1
CYrib2
BYrib1
Gwallplate
Hverticalrib
Irightwallplate
Hverticalrib
Jrighttopplate
Hverticalrib
Gwallplate
Hverticalrib
Gwallplate
Klefttopplate
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36
explodedbaseinnerstructure
Rfrontplate
Qrightskin
electronicsbaydoor
(notinBillofMaterials)
Mrearplate
Nrearplatedoor
Lleftskin
Oleftinnerskin Prightinnerskin
Innerassembly.
Seepage36for
explodedview.
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37
explodedbaseskins
Ucoverside
Scoverfront
Baseassembly.
Seepage37for
explodedview.
Tcovertop
Ucoverside
Vcoversidefiller
Vcoversidefiller
Wcoverrear
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38
explodedcover
0.75
6.25 4.25
0.75
14.75
0.75
1.5
0.75
1.5
0.75
1.5
.375
.375
.75
3.125 2.125
7.375
.375
0.75 0.75
.375
.375
.75
.75
.375
.375
.3125DIA.,2holes.
#1032threaded,2holes(frombottomside).
.375DIA.,2holes.
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39
1gantrybottom
stocksize:
.75x.75
material:
6061T6alum.
#required:
2
part#
1
4.5 6.5 6.5 6.5 6.5 6.5 6.5
3.25 3.25 3.25 3.25 3.25 3.25 2.25
6
3
3.00
1.50
0.75
25.5
0.75
0.75
.375 .375
12.75
.375
0.875
4.25
2.125
.4375
4.5 6.5 6.5 6.5 6.5 6.5 6.5
0.875
4.25
0.875
4.25
2.125
.4375
2.125
.4375
0.875
4.25
2.125
.4375
25.5
0.75
12.75 .375
1.5
1.5
.75
.75
3.25 3.25 3.25 3.25 3.25 3.25 2.25
48
24.00
.50DIA.,7holes.
.3125DIA.
.3125DIA.,7holes.
.3125DIA.
.3125DIA.,4holes,cut&filetoslots.
.3125DIA.,4holes,cut&filetoslots.
1.75
.875
.375DIA.,cut&filetoslots.
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40
2gantrytube
stocksize:
1.5x3.0x.125
material:
6063T52alum.
#required:
1
part#
2
0.75
6.25 4.25
0.75
14.75
0.75
1.5
0.75
1.5
0.75 0.75
7.375
2.125
.375 .375
3.125
.375
.75
.375 .375
.375
.75
#1032threaded,2holes.
.375DIA.,2holes.
8
4.00
.375DIA.
1/420threaded,
CBORE.375DIAx.25DP.,
2holes.
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3gantrylefttop
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#
3
0.75
2.5
6.25 4.25
0.75
2.5
14.75
0.75
1.5
0.75
1.5
0.75
2.5
0.75
2.5
3.75 7.5
7.375
2.125
.375
1.25
.375
1.25
3.125
.375
.75
.375
1.25
3.75 1.875
1.25
.375
.375
.75
.375DIA.,2holes.
1/420threaded,
CBORE.375DIAx.25DP.,
2holes.
#1032threaded,2holes.
#1032threaded,2holes.
.375DIA.,2holes.
1/420threaded,
CBORE.375DIAx.25DP.,2holes.
4 2
2.00 1.00
.25DIA.,2holes.
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4gantryrighttop
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#
4
0.75
1.5
0.25
11.25
2 7.5
.75
.375
1.00 3.75
5.625
.125
.3125DIA,2holes.
4 2
2.00 1.00
.25DIA,2holes.
1.75
.875
Notethatthispartisnot
symmetrical.Holesare
closertooneend.
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43
5gantryspacer
stocksize:
.125x.75
material:
6061T6alum.
#required:
1
part#
5
11.25
0.75
4 4
0.75 0.75
2 7.5
5.25 1.5
2
0.75
1.5
0.75
.375
.375 .375
.375
5.625
2.00 2.00
1.00
.75
.375
2.625 .75
1.00 3.75
#1032threaded,2holes
(fromrearside).
.3125DIA.,
2holes
1/420threaded,
CBORE.375x.50DP,2holes.
.3125DIA,2holes.
File/drilltoslots.
.375DIA.,2holes.
0.75 .375
0.5
.25
#1032threaded,2holes.
4
4
2.00
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44
6gantryouterright
stocksize:
.75x1.00
material:
6061T6alum.
#required:
1
part#
6
3.712
0.394
1.5
.75
1.856
.1875
2.5
1.25
4.5
2.25
0.606
.303
#1032threaded,
CBORE.25DIA.x.875DP.,2holes.
(CBOREfrombottom).
1/420threaded,CBORE.3125x.75DP.
1.25
.625
0.75
.375
0.75
1.5
.75
.375
.125R
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45
7Ymotormountfront
stocksize:
.75x1.25
material:
6061T6alum.
#required:
1
part#
7
3.712
0.394
0.606
1.5
.303
.75
1.856
.1875
2.5
1.25
4.5
2.25
#1032threaded,
CBORE.25DIA.x.875DP.,2holes.
(CBOREfrombottom).
1/420threaded,CBORE.3125x.75DP.
1.25
.625
0.75
.375
1.5
0.75
.75
.375
.125R
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46
8Ymotormountrear
stocksize:
.75x1.25
material:
6061T6alum.
#required:
1
part#
8
1.25
2.5
1.25
1.75
3.75
1.25
.625
.625
.875
1.875
0.75
.375
enlargedbelt
groovedetail.
0.8
.20 0.25
0.375
.094
.063
.3125DIA.,2holes.
1/420threaded.
0.75
.375
1.25
2
.625
1.00
.3125DIA.
1.25
2.5
1.25
.625
1.5
0.5
.75
.25
0.125
.062
45
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47
9Xbeltplate&10Xbeltclamp
stocksize:
.375x1.25
material:
6061T6alum.
#required:
1
part#s
9,10
ea.
PART#9 PART#10
6.5 6.5 6.5 6.5 6.5 6.5 3
45
2.5
5
1.25
2.50
1.50 3.25
22.50
3.25 3.25 3.25 3.25 3.25
0.5
.25
1/420threaded,7holes.
page
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48
11Yrail
stocksize:
.25x.2.50
material:
1018
coldrolledsteel
#required:
1
part#
11
0.75
13.5
1.75 5.875
1.75
0.75
1.75
0.75
1.5
0.75
0.75
1.5
0.75
1.75
3.375 6.75
0.75
1.75
6.75
.375
.875
2.9375 .875
.375
.875
.375
.75
.375
.75
.375
.875
3.375 1.6875
.875
.375
0.75
.375
.375
.375DIA.,2holes.NOTE:Thesetwoholes
areNOTcenteredinthematerialthickness.
1/420threaded,
CBORE.375DIAx.25DP,2holes.
(CBOREfrombottom).
#1032threaded,2holes.
.375DIA.,2holes.
#1032threaded,2holes(backside).
.375DIA.,2holes.
0.5
.25 0.813 .393
0.813
.393
page
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49
12carriageblockrearupper
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#
12
0.75
13.5
1.75 5.875
1.75
0.75
1.75
0.75
1.5
0.75
1.5
6.75
.375
.875
2.9375 .875
.375
.875
.375
.75
.75
.375
.375DIA.,2holes.NOTE:thesetwoholes
areNOTcenteredinthematerialthickness.
1/420threaded,
CBORE.375DIAx.75DP,
2holes.
#1032threaded,2holes(frombottom).
.375DIA.,2holes.
#1032threaded,2holes(frombackside).
.375DIA.,
2holes.
0.5
.25 0.813 .393
0.813
.393
0.75
.375
0.75
0.75
1.75
.375
.875
3.375
1.688
6.75
3.375
1
.50
2.5
1.25
0.75
1.75
.375
.875
1
1.5
.75
.50
.375
2.625 8.25 2.625
4.125 1.313 1.313
0.375 0.375
0.875
0.875
.438
.438
.188
0.375 0.375
0.875
0.875
.188
.438
.438
.1875DIA.,4holes.
R 0.25
.125R(Typ.)
1.25
.625
ALTERNATIVEDESIGN:
Ratherthancutnotchesatthe
cornersofthepart,leave
rectangular.Addcounterboresand
(2)additional#1032threadedholes
asindicated.Requiresuseoflonger
bolts(2")attwobearinglocations.
page
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50
13carriageblockrearlower
stocksize:
.75x1.25
material:
6061T6alum.
#required:
1
part#
13
2
0.5
0.5
0.5
1.5
0.5
0.875
1.75
0.375
3.5
1.00 .75
1.75
.25 .25
.4375
.875
.1875
.25
.25
2.75
1.375
.375DIA.
.3125DIA.,2holes.
#1032threaded,
CBORE.25DIAx.25DP,
2holes.
page
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51
14bearingblock
stocksize:
.75x1.00
material:
6061T6alum.
#required:
3
part#
14
2
0.5
0.5
0.5
1.5
0.5
0.875
1.75
0.375
1.375
1.375
3.5
1.00 .75
1.75
.25 .25
.4375
.875
.1875
.6875
.6875
.25
.25
.375DIA.
.3125DIA.,2holes.
#1032threaded,
CBORE.25DIAx.25DP,
2holes.
1/420threaded.
page
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52
15bearingblocktapped
stocksize:
.75x1.00
material:
6061T6alum.
#required:
1
part#
15
0.5
1
1.75 6.875
11.25
13 0.75
1.625
0.75 13
1.625
3.875 7.25
11.25
17
0.75
1.5
0.75
1.5
8.50
6.50 .375
.8125 5.625 .50
.25
.375
.75
.875 3.438
1.938 3.625
.375
.75
.8125
.375
5.625
6.50
1/420threaded,
CBORE.375DIA.x.25DP.,
2holes.
.375DIA.,2holes.
#1032threaded,2holes(bottomside).
.3125DIA.,2holes.
.375DIA.,2holes.
#1032threaded,2holes.
.375DIA.,2holes.
0.5
.25
page
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53
16carriageblockfrontright
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#
16
1.75 6.875
11.25
13 0.75
1.625
0.75 13
1.625
3.875 7.25
11.25
14.5
0.75
1.5
0.75
1.5
7.25
6.50 .375
.8125 5.625
.375
.75
.875
3.438
1.938 3.625
.375
.75
.8125
.375
5.625
6.50
1/420threaded,
CBORE.375DIA.x.25DP.,2holes.
(CBOREfrombottom).
.375DIA.,2holes.
#1032threaded,2holes.
.375DIA.,2holes.
#1032threaded,2holes.
.375DIA.,2holes.
0.5
.25
page
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54
17carriageblockfrontleft
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#
17
0.75
1.5
0.75
1.5
1.5
.75
.375
.375
.75
.75
.375DIA.
NOTE:
Usestockthicknessasthis
dimensiontomaintain
consistencybetweenpieces.
page
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55
18spacerupper
stocksize:
.75x.75
material:
6061T6alum.
#required:
2
part#
18
0.75
1.5
1.25
2.5
1.5
.75
.375
.625
.75
1.25
.375DIA.
page
version 2.1
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56
19spacerlower
stocksize:
.75x.75
material:
6061T6alum.
#required:
2
part#
19
0.394
1.5
0.394
3.538
5.326
0.5
1 2
2.75
1.856
.197
.197
.75
1.00
.50
.25
0.75
.375
R 1.25
.625R
.25DIA.,2holes.
.3125DIA.,2holes.
0.75
.375
1.856 1.682
EQUAL EQUAL
2.076
1.125
page
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57
20Zmotormountright
stocksize:
.75x1.00
material:
6061T6alum.
#required:
1
part#
20
0.5
1 2
1.00
.50
.25
0.75
.375
0.394
1.5
0.394
3.712
1.856
.197
.197
.75
R 1.25
.625R
5.5
2.75
.25DIA.,2holes.
1/420threaded,
CBORE.375DIA.x.25DP.,
2holes.
0.75
1.856 1.856
.375
EQUAL EQUAL
2
0.5
1
1.00
.50
.25
0.5
1.5
.25
.75
2.25
1.125
#1032threaded,
.75deep,2holes.
page
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21Zmotormountleft
stocksize:
.75x1.00
material:
6061T6alum.
#required:
1
part#
21
2.25
8.5
4.5
1.5
3
1
4.25
1.125
2.25
.75
.50
1.50
0.375
.1875
1.50DIA.
.25DIA.,4holes
.3125DIA.
1.856 1.856
.928 .928
4.5
1.856
1.856
2.25
.928
1.125
.928
R 0.25
.125R
2.25
NOTE:
Cutfrom2.50"wideplatestock,asitis
amorecommonstocksizethan2.25"
page
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59
22Zcableplate
stocksize:
.1875x2.50
material:
6061T6alum.
#required:
1
part#
22
enlargedbelt
groovedetail.
0.8
.20 0.25
0.375
.094
.063
0.5
1.5
.75
.25
.125R.
.3125DIA.
1.25
2.5
1.25
.625
0.75
.375
page
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60
23Ybeltclamp
stocksize:
.375x1.25
material:
6061T6alum.
#required:
1
part#
23
4.5 2.5
24
0.5
5
2.5
1.25
2.50
12.00
2.25 1.25
.25
1/420threaded,5holes.
1.75
.875
12.25
6.125
0.75
.375
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61
24Zrail
stocksize:
.25x2.50
material:
1018
coldrolledsteel
#required:
1
part#
24
22.5
1
2
1.5
.50
1.00
.75
11.25
.3125DIA.,5holes.
0.75
2.5 12.25 1.75 4.5
2.25 .875 6.125 1.25
.375
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62
25Zrailblock
stocksize:
.75x1.00
material:
6061T6alum.
#required:
1
part#
25
2.5
0.75
1.5
0.75
1.75
4
1.25 0.5
.25 .625
1.25 .75
.375
.875
2.00
.375
.3125DIA.,2holes.
1/420threaded,2holes.
page
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26nutplateblock
stocksize:
.75x1.25
material:
6061T6alum.
#required:
1
part#
26
5
1.35
0.973
1.25
0.75
.375
2.50
.675
0.675
1.875
.625
.338
.9375
0.875
.4375
0.675
1.35
.675
.338
.487
0.75
.375
.3125DIA.,2holes.
.50DIA.
.125DIA.,4holes.
1.5
.75
0.875
R 0.25
.125R
2.5
.4375
1.25
NOTE:
HolepatternisforDumpsterCNCanti
backlashnut.Modificationmaybe
necessaryifusingaanantibacklashnut
fromanothermanufacturer.
page
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64
27nutplate
stocksize:
.375x1.25
material:
6061T6alum.
#required:
1
part#
27
1.5
7.5 7.5 7.5 7.5 7.5 1.5
.75
3.75 3.75 3.75 3.75 3.75
.75
7.5
48
24.00
3.75
3
1.50
0.5
.25
1/420threaded,7holes.
page
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65
28Xrail
stocksize:
.25x1.50
material:
1018
coldrolledsteel
#required:
2
part#
28
48
2.5
2.5
0.251
0.246
1.25
1.25
.125
.125
24.00
1.5
7.5 7.5 7.5 7.5 7.5 7.5
1.5
1.5
.75
3.75 3.75 3.75 3.75 3.75 3.75
.75
.75
.3125DIA.,7holes.
.3125DIA.,7holes. Grind/file1/16"offoftopedge.
page
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66
29Xrailangleleft
stocksize:
1.25x1.25x.125
material:
A36
hotrolledsteel
#required:
1
part#
29
2.5
2.5
0.251
0.246
1.25
1.25
.125
.125
1.5
.75
48
24.00
1.5
7.5 7.5 7.5 7.5 7.5 7.5
.75
3.75 3.75 3.75 3.75 3.75 3.75
.3125DIA.,7holes.
.75R
1.251
.625
5.5
2.75
0.607
.30
.1875DIA.,2holes.
1.5
.75
.3125DIA.,7holes.
1.856
1.856
.928 .928
Grind/file1/16"offoftopedge.
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67
30Xrailangleright
stocksize:
1.25x1.25x.125
material:
A36
hotrolledsteel
#required:
1
part#
30
7.5 7.5 7.5 7.5 7.5 7.5
1.5
1.125
3.5
6
48
2.732
5.5
1.856
1.856
1.856 1.856
3.75 3.75 3.75 3.75 3.75 3.75
24.00
3.00
1.75
.5625
.928 .928
2.75
1.375
.928
.928
.3125DIA.,14holes.
.3125DIA.
.1875DIA.,4holes.
1.50DIA.
.75
0.375 .1875
4.5
2.25
0.75
.375
7.75
3.875
2.996 1.50
.375DIA.
page
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68
31Xplateright
stocksize:
.1875x3.00
material:
6061T6alum.
#required:
1
part#
31
7.5 7.5 7.5 7.5 7.5 7.5
1.5
48
3.75 3.75 3.75 3.75 3.75 3.75
24.00
.3125DIA.,14holes.
.75
0.375 .1875
1.125
3.5
1.75
.5625
6
3.00
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69
32Xplateleft
stocksize:
.1875x3.00
material:
6061T6alum.
#required:
1
part#
32
2.5
1.5
.75
.3125DIA.
1.25
0.75
.375
0.75
1
.375
.50
0.75
0.312
.375
.156
#1032threaded.
page
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70
33Xbeltpulleyadjuster
stocksize:
.375x1.25
material:
6061T6alum.
#required:
1
part#
33
1.5
1.5
0.75
.75
.75
.375
40
41.5
20.00
20.75
1.5
1.5
0.75
.75
.75
.375
20
21.5
10.00
10.75
.3125DIA.,2holes(atends).
.375DIA.,25holes,
.75centertocenter.
NOTE:theseare
lighteningholesand
areoptional.
Radiusbothends.
.3125DIA.,2holes(atends).
.375DIA.,12holes,
.75centertocenter.
NOTE:theseare
lighteningholesand
areoptional.
page
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71
34&35cablearms
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#s
34,35
PART#34
PART#35
ea.
0.75
5
1.5
1.5
0.75
.375
.75
2.50
0.75
.375
.375
.75
0.5
.25
2
1.00
.3125DIA.
.3125DIA.,2holes.
page
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72
36cablearmmountingblock
stocksize:
.75x.75
material:
6061T6alum.
#required:
1
part#
36
0.625 0.625
.3125 .3125
7.25
3.625
1/420threaded. .3125DIA.
1/420threaded,
.3125CBOREtoleave
.50"threadlength.
0.75
1.5
.375
.75
2
1.00
1
.50
1.125
.563
0.375
45 45
1.375
4.25
8.5
4.25
2.125
.688
.1875
0.75
.375
30
30
3.5
1.75
R 2.419 R 2.625
1.3125R
1.21R
0.75
.375
R 0.125
.062R
R 0.5
.25R
2.054
1.00
R 0.188
.094R
for:RIDGIDR2401
page
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73
37routermountRidgidR2401
stocksize:
.75x1.75
material:
6061T6alum.
#required:
2
part#
37
for:RIDGIDR2401
0.625 0.625
.3125 .3125
7.25
3.625
.3125DIA.,2holes.
0.75
1.5
.375
.75
1.5
.75
1.5
0.875
.75
45 45
0.75
.375
R 2.419 R 2.625
1.3125R
1.21R
R 0.125
.062R
.4375
2.5 1.25
1.75 5 1.75
.875 .875 2.50
8.5
4.25
R 0.25
.125R
page
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74
38routerclampRidgidR2401
stocksize:
.75x1.25
material:
6061T6alum.
#required:
2
part#
38
8.5
4.25
2
1.00
1
.50
30
30
3.5
1.75
4.25
2.125
1.125
.563
1.375
.688
0.875
.4375
60 60
2.054
1.00
0.75
.375
R 0.5
.25R
R 0.188
.094R
0.625 0.625
.3125 .3125
7.25
3.625
1/420threaded. .3125DIA. 1/420threaded,
.3125CBOREtoleave
.50"threadlength.
0.75
1.5
.375
.75
0.75
.375
R 0.125
.062R
for:BOSCHCOLT
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75
39routermountBoschColttop
stocksize:
.75x1.75
material:
6061T6alum.
#required:
1
part#
39
8.5
4.25
2
1.00
1
.50
30
30
3.5
1.75
4.25
2.125
1.125
.563
1.375
.688
R 2.776
1.388R 1.50R
0.875
.4375
45 45
2.054
1.00
0.75
.375
R 0.5
.25R
R 0.188
.094R
0.625 0.625
.3125 .3125
7.25
3.625
1/420threaded. .3125DIA.
1/420threaded,
.3125CBOREtoleave
.50"threadlength.
0.75
1.5
.375
.75
0.75
.375
R 0.125
.062R
for:BOSCHCOLT
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76
40routermountBoschColtbottom
stocksize:
.75x1.75
material:
6061T6alum.
#required:
1
part#
40
R 2.776
1.388R
R 3
1.50R
1.375
.6875
1.5
2.5
.75
1.25
1.75 1.75
.875 .875
1.5
.75
8.5
4.25
5
2.50
0.75
.375
R 0.25
.125R
0.625 0.625
.3125 .3125
7.25
3.625
.3125DIA.,2holes.
0.75
1.5
.375
.75
R 0.125
.062R
for:BOSCHCOLT
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77
41routerclampBoschColttop
stocksize:
.75x1.25
material:
6061T6alum.
#required:
1
part#
41
R 2.776
1.388R
R 3
1.50R
1.375
.6875
1.5
2.5
.75
1.25
1.75 1.75
.875 .875
1.5
.75
8.5
4.25
5
2.50
R 0.25
.125R
0.625 0.625
.3125 .3125
7.25
3.625
.3125DIA.,2holes.
0.75
1.5
.375
.75
45
45
0.75
.375
R 0.125
.062R
for:BOSCHCOLT
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78
42routerclampBoschColtbottom
stocksize:
.75x1.25
material:
6061T6alum.
#required:
1
part#
42
2
2
0.375
1.25
0.5
1.125
0.75
.375
1.00
.625
.25
.625
.188
1.00
R 0.125
.063R
1.5
1.25
.625
.75
2.75
0.5
1.25
1.25
0.625
2.75
0.375
0.75
0.75
0.25
.625
.313
.625
1.375
1.375
.375
.188
.125
.375
R 0.25
.125R
.125R
2.5
0.625
1.25
2.5
0.5
0.375
0.375
0.375
0.75 1.5
1.5
.375
.188
.75
.188
1.25
.188
.25
.625
.313
1.25
.75
R 0.27
.125R
R 0.25
.125R
.125dia.,2holes.
.125dia.,2holes.
.125dia.,2holes.
.25
R 0.188
.093R
page
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79
43,44,45limitswitchbrackets
PART#43
Xlimitswitchbracket
(2)required
PART#44
Ylimitswitchbracket
(2)required
PART#45
Zlimitswitchbracket
(1)required
stocksize:
.1875x2.50
material:
6061T6alum.
#required:
asindicated
NOTE:
Allbracketsaredimensionedfor
RadioShackswitch,part#275016.
Useofotherswitchesmayrequire
modificationofbracketdesign.
NOTE:
Stocksizeislistedas.1875x2.50,
asthesecanbecutfromthe
remainingmaterialthatisspecified
forpart#22(Zcableplate.)
(F)topskin
PLYWOODLAYOUTNOTES:
Thesearesuggestedlayoutofpartson4'x8'
plywoodsheets.
Allowforwidthofsawcuts.
Dashedlinesindicatecutstobemadelater.
(A)bottomskin
(B)Yrib1
(B)Yrib1
(C)Yrib2
(C)Yrib2
(O)leftinnerskin
(M)rearplate
(H)verticalrib (H)verticalrib
(H)verticalrib (H)verticalrib
(H)verticalrib (H)verticalrib
(K)lefttopplate
(J)righttopplate
(N)rearplatedoor
(Q)rightskin
(L)leftskin
(P)rightinnerskin
(
D
)

r
i
b

1
(
E
)

r
i
b

2
(
D
)

r
i
b

1
(
E
)

r
i
b

2
(I)rightwallplate
(G)wallplate
(G)wallplate
(G)wallplate
(R)frontplate
(E)Xrib2
(E)Xrib2
(E)Xrib2
4'x8'sheet,
3/4"finishsandedplywood,
suchas"cabinetgrade."
(U)coverside
(U)coverside
(W)coverrear
(T)covertop
(V)coversidefiller
(V)coversidefiller
(S)coverfront
page
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80
plywoodsheetlayouts
X2
NOTE:Allslots3/4"nominalwidth,
centeredondimensioncenterlines.
Adjustactualslotwidthforlightpressfit
withmeasuredthicknessofribmaterial.
31
26
26.00
31.00
23
2.5
23
23.00
23.00
2.50
1.25
2.5
2.50
1.25
8.25 7.375
7.375 8.25
3
31
3
31.00
3.00 3.00
3 3
3.00 3.00
0.75
0.75
26
26.00
0.75
0.75
.75
.75
.75
.75
31
2.5
31.00
2.50
6.5 6.375 6.375 6.5
1.875
29.5
1.25
2.5
29.50
6.50 6.375 6.375 6.50
1.875
2.50
1.25
1.875
1.875
(A)bottomskin
(1)Required
(F)topskin
(1)Required
(B)Yrib1
(2)Required
(D)Xrib1
(2)Required
(C)Yrib2
(2)Required
(E)Xrib2
(5)Required
page
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plywoodpartsAF
stocksize:
3/4"thickness
material:
finishsanded
plywood
#required:
asindicated
NOTE:
Cutopeningforpassthrough
ofwiresinonerib.Itdoesnotneed
tobethisexactsizeandshape.
24.5
3
3.00
24.50
8.5
3
8.50
3.00
24.5
2.75 2.625
2.438
3
2.75
2.625
25.25
1.688
25.25
3
3.00
3.00
2.50
2.625
2.75
24.50
1.688
0.188
.188
1.498
1.50
0.179
2.447
3
1.498
2.438
25.25
3.00
2.50
2.625
2.75
.188
25.25
26
14
26.00
14.00
31
3
25
3
31.00
25.00
3.00 3.00
4
6.75
2.5
13.25
4.00
2.50
6.75
13.25
26.5
8.25
8.25
26.50
A
A
SectionAA
45
1.5
.75
2.438
1.50
1.50DIA.
1.50DIA.
(G)wallplate
(3)Required
(H)verticalrib
(6)Required
(i)rightwallplate
(1)Required
(j)righttopplate
(1)Required
(K)lefttopplate
(1)Required
(L)leftskin
(1)Required
(M)rearplate
(1)Required
(N)rearplatedoor
(1)Required
page
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82
plywoodpartsGN
stocksize:
3/4"thickness
asindicated
#required:
material:
finishsanded
plywood
SectionAA
A
A
45
1.5
.75
Typicalpocket,
enlargeddetail.
2 2
8
4
2.00
1.00 1.00
4.00
pocketrouted5/8"deep
A
A
A
A
0.75
26
3 6.625
4
10
0.75
26
6.625 3
4
10
26.00
3.00 6.625
.75
4.00
10.00
10.00
26.00
.75
4.00
6.625 3.00
2
10
2
10
2
26
4.75
6.5
14
26.00
10.00 10.00
14.00
2.00 2.00 2.00
4.75
6.50
31
13.25
3 25 3
3.00 25.00 3.00
10.75
2.5
2.50
10.75
13.25
31.00
(O)leftinnerskin
(1)Required
(P)rightinnerskin
(1)Required
(Q)rightskin
(1)Required
(R)frontplate
(1)Required
page
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83
plywoodpartsOR
stocksize:
3/4"thickness
asindicated
#required:
material:
finishsanded
plywood
SectionAA
45
1.5
.75
Scoverfront
(1)Required
32.5
13
32.5
26.75
32.50
26.75
32.50
13.00
27
22.25
A A
A A
A
A
27.00
22.25
R 1.5
R 1.5 1.5R 1.5R
26
11.5
11.5
3
3.00
11.50
26.00
11.50
Tcovertop
(1)Required
Wcoverrear
(1)Required
Ucoverside
(2)Required
Vcoversidefiller
(2)Required
NOTE:
Alldashedlinesindicatecuts
tobemadelaterinthe
assemblysequence.
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84
plywoodpartsSW
stocksize:
3/4"thickness
asindicated
#required:
material:
finishsanded
plywood
20
16
7.75
4
2
4.00
7.75
2.00
20.00
P1coverwindowfront
(1)Required
P2coverwindowtop
(1)Required
P3coverwindowside
(2)Required
24
8
P3
P3
P1
P2
PLASTICLAYOUTNOTES:
Belowisasuggestedlayoutofpartson
24"X24"polycarbonatesheet.
Leavespaceforwidthofsawcuts.
24"x24"polycarbonatesheet.
R 2
2.00R,typ.
R 2
2.00R,typ.
R 0.75
.75R,typ.
16.00
8.00
24.00
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85
coverplastic
stocksize:
.125"min.
thickness
material:
polycarbonate
sheet
#required:
asindicated
0.223
file/grindheadofbolt
toleaveapproximately
3/32"thickness
remaining.
3/32"
5/16x11/2"bolt
1.173
5/8"
washertofit5/16bolt.
Outsidediametersofwashersmayvary.
Makesureouterdiameterislargerthan
theoutsidediameterofthe22mm
bearings.Ifitisnot,useawasherwitha
largeroutsidediameter.
fileinsidediameterto
approximately5/8"
(8)modifiedboltsrequired
washerW1
(6)modifiedwashersrequired
1/420x1/2"bolt
shortenbolttoapprox.
3/8"threadlength.
TheseattachtheXrailsto
therailangles,andmay
needtobetestedand
adjustedforexactlength
required.
(14)modifiedboltsrequired
page
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modifiedhardware
23
0.75
0.75
foryrib1
foryrib1
forxrib1
forfrontplate
forrearplate
23.00
centeredon
panelwidth
.75
.75
29.5
29.50
centeredon
panellength
forxrib1
1.5
6.25 6.25
1.50
equal equal
12
12.00
2.25
3.5 3.5 equal equal
2.25
Scoverfront
Tcovertop
Abottomskin
NOTE:
Markallredlinesontopanelswitha
pencilasindicated.Seeassembly
directionsformoredetaileddescription
ofthesemarkedlines.
Measureasindicatedindrawings,anduse
previouslycutplasticwindowsastemplates
totrace.Tracelinestightlytowindow.
11.595
4.975
11.6
5.00
1.5
2.5
1.50
2.50
Ucoverside
11.595
4.975
5.00
11.6
1.5
2.5
1.50
2.50
Ucoverside
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panelmarkups
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woodfabrication
Allofthewoodpartscanbefabricatedwithrelativelysimple
woodworkingequipment.Allofthebasiccuttingcanbe
accomplishedwithacircularsaw,suchastheonepicturedto
theright.Whencombinedwithastraightedgefencewhichcan
beclampedtothesheetmaterial,itwillbecapableofjustabout
allcuttingneedsinthisproject.
Atablesawwouldbeusefulforcuttingrepetitivepartsofthe
samewidth,suchastheinnerribs,tomakeiteasiertokeeptheir
dimensionsconsistent.However,withcarefulfencesetup,
thesecomponentscanalsobecutwithacircularsaw.
Thefewcutsthatcan'teasilybedonewithacircularsawor
tablesawcaneasilybedonewitharouter.Thisprojectis
designedtouseatrimrouter,suchastheonetotheright,
asthespindle.Purchasingtherouteratthebeginningofthe
projectwillallowittobeusedtocutsmallcutoutsand
pocketsthatarefoundonseveralofthecomponents,aswell
ascurvedcuts.
Routermountdrawingsareprovidedfortwomodels,the
RidgidR2401andtheBoschColt.Themountdesigncanbe
alteredandadaptedformostsimilarlysizedtrimrouter.
Theuseofspiralupcutbits,ratherthanstraighttypebits,is
suggested.Thesearesimilarinformtoendmillsusedina
millingmachine,buthavefluteanglesandcuttingangles
thatarespecificallysuitedforwood.Theincreaseincutting
performanceoverstraightbitsiswellworthanyadditional
cost.
Boththecircularsawandtheroutercanbeusedwithafenceto
increasetheiraccuracy.Commerciallyproducedfenceswith
integralclampsareavailable.Alternatively,astraight,rigidlength
ofmetalcanalsobeused.Picturedtotherightisalengthof1"x
2"rectangularaluminumtubingandtwoCclampstosecureitin
place.Withcarefulsetup,veryaccuratecutscanbe
accomplished.
Don'tforgetbothhearingandeyeprotection.Thesearenot
optional!
WOODFABRICATION
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woodfabrication
Afewsimplelayouttoolsarerequired.Agoodquality
framingsquare,atriangleormachinist'ssquare,tapemeasure,
andapencil.Makesurethesquareandtriangleareactuallyat
90degrees.Itmayseemobviousthatthelegswouldbe
exactlyperpendicular,butlowqualityversionscanbevery
inaccurate.Youcancheckaccuracybyplacingitalonga
knownstraightedgeandstrikingaperpendicularmark.Flip
thesquareortriangle180degreesandmakeanothermark
paralleltothefirst.Ifitisinsquare,thelineswillbeexactly
parallel.Ifnot,thelineswillbeclosertogetheratoneendor
theother.Notethatthistestisonlyasaccurateasthe
straightedgeyouareusing.
Whendrillingholesinwood,asetofbradpointdrillbitsis
worththeinvestment.Theycutaconsiderablycleanerholethan
regulartwistbits,whichareintendedprimarilyformetal.
Inadditiontothetoolsshown,youwillmostlikelyneedafew
othertraditionalhandtools,suchasahandsaw,woodchisels,
hammer,anailset,etc..Anelectricsanderwillalsobehelpful
inpreparingthewoodsurfacespriortopainting.
Whateverselectionoftoolsyouendupusing,whatismost
importantisaccuracyoflayoutandcutting.Becarefultomake
precisemeasurementsandthin,crisppencilmarks.Cuttothe
wastesideoftheline,asseeninthephotototheright,to
maintainthedesireddimensionsofthefinishedpieces.
Okay,timetorefertothedrawingsheetsforthewoodpartsand
startcutting!Cutallofthewoodpartsonpages8084totheir
overallsizes.
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woodfabrication
Withallofthewoodcomponentscuttotheiroverallsizes,
thereareseveralwhichhavesmallerspecialtycuts.
Theinnerskinpanelseachcontaintwopockets.Theseshould
becutwiththerouter,priortocuttingthe45degreebevel
alongtheedgesofthepanels.Markthelocationsofthe
pocketsandsetthedepthofcuttoabout1/8"lessthanthe
thicknessofthematerial.Routthepocketstowithin1/8"of
themarkedlines.
Afterfirstremovingmaterialtowithin1/8"ofthemarked
lines,returnforafinishpassthatcutsrighttotheline.
Thecutsshowntotherightweredoneentirelybyhand,but
thefencecanbeusedtoincreasethestraightnessofthecuts.
Exactsizeandprecisionofthesepocketsisnotrequired,as
theyarepresentonlytoprovidewrenchclearancewhile
servicingthemachine.
Afterthepocketsarerouted,cutthe45degreebevelsonthe
topedges,asseenintheimagetotheleft.Thiscanbedone
eitheronatablesaw,orwithacircularsawandfence.
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woodfabrication
Thereroundholesinseveralparts,suchastheonemarked
intheimagetotheleft.Thesecutsarebestaccomplished
withaholesaw.Severalofthemetalcomponentsalso
haveholesofthesamesize,sopurchaseof"bimetal"hole
sawswillallowcuttingbothmaterials.Twosizesofhole
saws,11/4"and11/2,willservetocutalllargeround
holesintheproject.
Drillingoneormoreholestangenttotheoutsidediameter
ofthefinalhole,asshowntotheleft,willprovidespacefor
chipstoclear.Thiswillmakethesawingoperationmuch
easier.Aholeatthecentermayalsobepredrilled,toact
asapilottoalignwiththecenterdrillthatisintegratedinto
theholesaw.
Usingtheholesawinadrillpressatalowspindlespeedis
suggested,aswellasusingapieceofscrapwoodasa
backupboardtoavoidsplintersonthebackofthecut.The
finishedcut,andtheplugthatwillneedtoberemovedfrom
thesaw,shouldlookliketheimagetothelowerleft.
Asseenintheseriesofimagestotheright,several
componentshavesquareholesinthem.Thesecaneasilybe
accomplishedbydrillingaseriesofholeswiththeholesaw
toremoveabulkofthematerial.Theroutercanthenbeused
toremovetheremainingmaterial.
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woodfabrication
Manyoftheinternalribcomponentscontainnotches,which
allowthemtoslidetogetherwithperpendicularribs.To
maintainconsistencyinlocation,thesearebestcutacrossall
ribsofthesametypeinoneoperation.Thiscanbe
accomplishedwithacircularsawasseentotheright.
Clampandmarkthecutsontheribs.Measurethethickness
ofthewoodstock,andmarkthecutstocorrespondtothis
thickness.Correctslotwidthwillresultinasmallamountof
forcebeingrequiredtoassembletheribs.
Setthesawbladedepthdimensiontojustoveronehalfof
theribwidth.Carefullymakeacuttotheinsideofeachof
themarkedlines.
Makeaseriesofcloselyspacedcutstoremovetherestofthe
materialfromtheslot,asshowntotheright.
Thesecutscanalsobemadeonatablesawwithadadoblade,
orwitharadialarmsaw.Thecutscouldalsobemadewitha
handsaw,preferablyinamiterbox,andusingachiselto
removethewastematerialfromtheslot.
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woodfabrication
Asshownintheseriesofimagestotheleft,oneribrequiresa
passthroughtoaccommodatewiringfortheelectronics.
Thus,itssizeisnotcrucial.Thesuggestedsize,indicatedon
thedrawings,leavesadequatematerialtoallownailinginto
thispiece.
Thiscutcanalsobemadebyremovingabulkofthematerial
withaholesaw,andfinishingwiththerouter.
Cutthepolycarbonatematerialforthecoverwindows,as
shownintheimagetotheright.Leavetheprotectivefilm
attachedtotheplasticwhilemakingthecuts.
Ifthepolycarbonatebeingusedisrelativelythin,lessthan
about1/8",itmaybecarefullycutwithautilityknife.Itmay
alsobecutwithacircularsawandastandardfinetoothfinish
blade.
Regardlessofmethod,usethefencetoclamptheplasticsheet
toascrapsheetofwoodwhilemakingthecuts.
Theimagetotherightshowsallofthewoodcomponents
forthebase.
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woodbaseassembly
Onthebottomskin(partA),drawthepatternoflinesthatareshown
inredinthediagramtotheleft.Thelinesareallspaced3/4"apart.
Amoredetaileddrawingoftheselayoutlinesisshownonpage87.
SlidetheXandYribstogetherasshowninthemiddleleftphoto.
Drill3/16"clearanceholesasshownintheleftphotos,and
generouslycountersink.
Placetheassembledribsontothebottomskinasshowninthetop
rightphoto.Theendsoftheribsshouldallfallalongthedrawn
layoutlinesasshown.Withapencil,markaroundeachribontothe
bottomskin,asshowntotheright.
ASSEMBLYOFWOODCOMPONENTS
Removetheribassemblyfromthebottomskin.Thepenciled
riboutlineswillbeusedasguidesforglueapplication.
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woodbaseassembly
Asshownintheseriesofimagestotheleft,applycarpenter's
gluetotheareawheretheribsmeetthelowerskin.Reposition
theribsontheskinandattachwith#10x3"woodscrews.Use
cautionthattheassemblydoesnotshiftasthescrewsare
tightened.Thewetgluecanactasalubricantandallowthe
piecestoslideeasily.Alsobesurethatnoneofthescrewheads
areproudofthetopfacesoftheribs,astheywillinterferewith
laterplacementofthetopskin.
Asseeninthelowerleftimage,applygluetothefrontedgesof
theribsandtothelowerskinasshown.
PositionthetwoYrib1(partsB)andclampasshowntothe
right.
Withclamppressureapplied,securethetwoYrib1partstothe
lowerskinwiththe#10x3"woodscrews.Oncefullysecuredto
thelowerskin,attachwith#6finishnailsintotheendgrainof
theXribs,asindicatedintheredcirclestotheright.Useanail
setifnecessary,sothattheheadsarebelowthesurface.
Usingthesamemethodandsequenceofgluing,clamping,
andnailing,attachthetwoXrib1partsasshowntothe
right.Thebaseisnowreadyforattachmentofthetopskin.
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woodbaseassembly
Asshownintheimagetotheleft,positionthetopskinonthe
base.Offsettheskinineachdirection,andtransferthe
centerlinesoftheribstotopoftheskinwithpencillines.These
lineswillbeusedasaguideforfasteningthetopskin.
Removethetopskin,applycarpenter'sgluetothetopsofallribs,
andcarefullypositiontheskin.Usingthelinesasguides,nail
throughtheskinandintotheribswith#6finishnails.The
assemblyshouldlooklikethelowerleftimage.
Asshownintheupperrightimage,applygluetotheendYrib.
Spreaditsothatitevenlycoatsthesurface.Positionthefront
plate(partR),andsecurewith#6finishnailsintotherib.Then
nailalongtheedgesofthetopandbottomskinsintothefront
plate,asshownintherightimage.
Installtherearplate(partM)inthesamemanner.Thebase
assemblyshouldnowlookliketheimagetotheright.
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woodbaseassembly
Asshownintheimagetotheright,assembletheverticalribs
(partsH)tothelowerwallplates(partsG.)Attachwith#6
finishnailsandcarpenter'sglue.Thecenterverticalribis
centeredalongthelengthofthewallplate.
Priortoassembling,drillandcountersinkclearanceholesfor
installationof#10screwsthroughthewallplatesandoutside
verticalribsasshown.
Slidetheassembliesdownbetweenthefrontandrearplates
untiltheyareinfirmcontactwiththetopskinofthebase.Place
astraightedgeacrossthetopsoftheribsasshownintheimage
totheright.Iftheyarenotallexactlythesameheight,either
trimtheonesthataretallerorshimtheshorteronesas
necessary,sothattheirtopsareparalleltothebase.Measure
uptothestraightedgeatseveralpointstocheckthis.Shimscan
bemadeofpaperorthinpaperboardifnecessary.Thetopsof
theribsneedtobeexactlythesameheightsothatthetopplate
willbeflatwheninstalled.
Whenthealignmentoftheverticalribsissatisfactory,
removetheassembliesfromthebase.Applyandspread
gluetothematingsurfaces,andreposition.Attachthelower
wallplatetothebasewith#10x11/4"woodscrews.With
thelowerplatessecurelyfastened,securetheverticalribs
tothefrontandrearplateswiththe#10x11/4"screws.
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woodbaseassembly
Trialfitthetopwallplatesasshownintheimagetotheleft.If
theplywoodmaterialisthinnerthanthefull3/4"thatis
specified,thetopoftheplatemaybeslightlylowerthanthetop
edgeofthefrontand/orrearplate,asseentotheleft.
Ifthetopplateexhibitsthiscondition,trimthefront/rearplates
asshowninthelowerleftimage.Applygluetothemating
surfacesandinstallthetopwallplateswith#6finishnails.
(Notpictured)Withthesidewallsinplace,theinnerandouter
skins(partsL,O,Q,andP)canbefastenedtothebaseassembly
with6dfinishnails.Usetheexplodedviewdrawingonpage37
asaguide.Thetopedgesoftheouterskinsshouldbeflushwith
thetopsurfacesofthewallplates.Thebottomedgesofthe
innerskinsshouldsitflushagainstthetopskin.
PositiontheXplates(parts#31and32)ontothetopoftheir
correspondingtopwallplates(partsKandJ.)Besurethat
thecorrectendsoftheXplatesarefacingforward.Alignthe
rearedgesofthecomponentssothattheyareflush.Witha
pencil,tracethelocationsoftheholesinthealuminumparts
tothewoodparts,asshownintheimagetotheright.
Asshowntotheright,drilla1/8"pilotholeinthecenterof
eachholelocationthatwastransferred.
Betweenandaroundthisfirstseriesofholes,drillanother
seriesofclearanceholesfor#10woodscrews.Countersink
thissecondsetofholes.
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woodbaseassembly
Applyandspreadgluetothematingsurfaces,andfastenthe
topplates(partsKandJ)with#10x11/4screws.Thetop
platesarepositionedexactlyabovetheplatesbeneaththem.
Therearedgeofthetopplatesshouldbeflushwiththerear
surfaceoftherearplate.Thisshouldleaveonethicknessof
plywoodremainingatthefrontandsidesofthemachine,as
seenintheimagetotheright.
Thebaseisnowcomplete,andshouldlookliketheimagetothe
right.Sandanyproudedges,setthenailheadsbelowfinish
surfaces,andfillheadswithwoodfiller.Thebasecannowbe
primedandpainted.
Measuringbetweenthetwotopplates,asshownintheright
image,thedimensionshouldbe25.00",andbeparallelfrom
fronttorear.Ifitissmallerthanthisdimension,theinsideedge
(s)ofthetopplatescanbecarefullytrimmedwiththerouter
andaguideorfence.
Ifthedimensionmeasuresslightlylargerthan25"itcanbeleft
asitis.
25.00"
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coverassembly
Markthewindowlocationsonthecorrespondingplywood
coverparts.Referencethedrawingonpage87for
dimensionsoftheselocations.Usethepreviouslycut
plasticwindowpanelsastemplates,andtracearound
themasshowntotheleft.
Drawasecondseriesoflines,offset3/8"totheinsideofthe
windowoutlines,asshowntotheright.
Usingtherouter,removematerialtotheinsideofthetwo
lines.Aholesawcanbeusedtoremovelargequantitiesof
materialclosetotheline.Thesecutscanbedonefreehandif
youarecomfortabletodosowiththerouter.Astheyarenot
criticalforfitofotherparts,anycuttingerrorwillonlyeffect
appearance.
Settheroutercuttingdepthto1/32"1/16"greaterthanthe
thicknessoftheplasticwindowmaterial.Routthisdepthto
thepenciloutlineofthewindows,toprovidearabbetforthe
installationoftheplastic.Whilerouting,checkthefitofthe
plasticinthedepressionoften.
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coverassembly
Whentherabbetshavebeencutfortheinstallationofthe
plasticwindows,assemblyofthecovercanbegin.Asseen
intheimagetotheleft,assemblethecoversides(partsU)
tothefillerpieces(partsV)withglueandnails.
Attachoneofthesideassembliestothecovertop(partT)
asseentotheright.Whilenailingtogether,becarefulnot
toplacenailsclosetotheangledpencillinesthatextend
upthesidesandacrossthetop.Asawcutwilllaterbe
madealongthisline.Keepinganynailsatleast1.5from
thislinewillbeasafedistance.
Attachthecoverfront(partS)totheassembly.Measure
andmarkacenterlineonthefrontandtopparts,sothat
thefrontwillbecenteredwhenitisinstalled.Usecareto
ensurethatthetopandsideareassquareaspossible
whenattachingthecoverfront.Asseenintheupperright
photo,acarefullyscribedpencillinecanbeusedasa
guidetohelptomaintainsquareness.Glueandnailthe
coverfronttothetopalongitsedge.Attachthesidefiller
tothefrontwithscrewsfromtherear.Inthetopright
image,itcanbeseenthatclearanceholesforthese
screwshavebeenpredrilled.
Therestofthecoverassemblywillusethemachinebase
asaworkingsupport,toensurethatthecoverfitsas
tightlyaspossible.
Standtheleftsideassemblyinpositiononthebase,as
seenintheimagetotheright.
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coverassembly
Placetheassembledcoverpiecesontotheleftsideassembly,
whichisstandingonthebase,andfastenwithglue,nails,
andscrewsaswereusedontherightside.Checkforcorrect
alignmentandsquarenessmultipletimes,beforeandduring
attachment.
Withthecoverassemblystillstandingonthebase,attachthe
rearpanel(partW.)Attachittotheedgesofthecover
assembly,butdonotattachittothebaseatthistime.
Asseentotheright,carefullymeasureandclampafenceto
allowcuttingalongtheanglemarksonthesidepieceswitha
circularsaw.Setthebladedepthasdeepaspossible,tocut
partiallyintothecovertop.
Withbothsidecutsmade,repositionthefencetocutacross
thecovertop.Settingthesawbladeata30degreetiltwill
allowittoalignwiththesidecuts.Carefullypositionthe
fencesothatthecutswillalignattheirends.Aftercutting,the
coverwillnowbeintwopieces.
Asseentotheupperleft,markandcutashallowrabbetforthe
pianohinge,usingtherouter.Cornersoftherabbetmayneedto
becleanedoutsquarewithawoodchisel.Checkthefitofthe
hingeasseentotheleft.Whenthehingeisinstalledthereshould
beagapbetweenthetwocoverpiecesthatisthethicknessofthe
circularsawblade.
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coverwindowsandhinge
Removethecoverfromthebase.Thepartscannowbesanded,
finished,andpainted.
Itcanbehelpfultoplanwherewiringwillberunforthemachine
electronicsbeforepaintingthebase.Asseenintheimagetothe
right,twoholeswerecutwithaholesawforwiringtopassfrom
theelectronicscompartmenttothecablemanagementarms.A
holewasalsocutintotherearplatedoor(partN)fortherouter
cord.Thedoorwillbeinstalledduringalaterstage.
Placethetwohalvesofthecoverassemblyonthebase.Withall
oftheedgesofthecoversittingtightlytothebase,thereshould
beagapbetweenthetwohalvesthatisequaltothethicknessof
thecircularsawblade.
Whilemaintainingthisconsistentgap,installthepiano
hingetothetwocoverhalves.Theassemblyshouldlook
liketheimagetotheleft.
Withthetwohalvesconnectedviathehinge,installthe
plasticwindows.Applyathinbeadofsiliconeadhesivein
thewindowrabbet.Spreadittoaneventhickness.Donot
applyanexcessiveamount,asitwillbepushedfromthe
grooveandontothesurfaceoftheplasticwindow,which
willbeunsightly.Removeanyprotectivefilmfromthe
windowsandcarefullysettheplasticintotheadhesive.
Presslightlytoset.Theinstalledwindowsshouldsit
flushtothecoversurfaces,asintheimagetotheright.
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metalpartsfabricationsequence
FABRICATINGTHEMETALPARTS:
Themostefficientmethodoffabricatingthemetalpartsistodoeachtypeof
operationallatonce.Moreindepthdescriptionsofeachstepareonthe
followingpages.Thefollowingfabricationsequencewasusedhere:
1. Cutallofthepiecestotheiroveralllengths.
Ifnecessary,filethecutendsofthepartswhileholdingtheminavise,toclean
themupandmakethemasperpendicularaspossibletothepart.
2. Layoutalllocationsofholesandanysecondarycutswithamarkerand
scribe.
3. Centerpunchalloftheholes.
Useaspringloadedcenterpunchforaccuracyandspeed.
4. Drillallholes.
Itmaybequickesttodrillallofeachsizeholeatonce.Keepthesamesizedrill
bitchuckedinthedrillpressanddrillallholesofthatsizeinalloftheparts
beforechangingbits.Itmaybefastertoclampandunclamppartsinthedrill
pressvicethantoconstantlychangedrillbitsizewhileworkingononlyonepart
atatime.
5. Drillcounterbores.
Hereitmaybeeasiesttodrilltheprimaryhole,keepthepartclamped,change
thebit,andthendrillthecounterbore.Thiswillmaintainconcentricity.
6. Tapallthreadedholes.
7. Cutthelargeandcomplexpartshapes,suchastheroutermounts,by
stitchdrillingaseriesofcloselyspacedholestonibblethroughthematerial.
Useahandfiletofinishtheparts.
8. Fabricatethestuds.
Referencingthestudscheduleonpage29,cutallofthesteelstudstolength
fromthreadedrod.Filetheendsflat,withachamferaroundtheedge.
Threadinganutontotherodbeforecuttingcanhelpstraightenanythread
deformationasitisremoved.However,thismethodshouldbeunnecessaryif
finishfilingisdoneproperly.
Keepthefinishedstudsorganizedbysize.
9. Fabricatethemodifiedhardware.
Referencingthedrawingsonpage86,modifytheboltsandwashersas
indicated.Thesemodificationscanallbedonewithahandfile.Keepthese
finishedpartsorganizedaswell.
MetalFabricationSequence
1. CutLengths
2. HoleLayout
3. CenterpunchHoles
4. DrillHoles
5. Counterbore
6. TapHoles
7. PlateCuts
8. Studs
9. Hardware
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clampingtools
METALFABRICATION
Mostviseshavejawfacesthatareserrated.Usingtheseto
clampaluminumpartscanbadlymarthefinishsurface.
Thesolutionistobuyorfabricateasetofjawcovers.There
arecommercialversionsavailableinmanytypesofnon
marringmaterials:brass,plastic,rubber,etc.Theimagesto
therightillustrateasetofcoversthatwerequicklyfabricated
fromapieceofcommonaluminumroofingflashing.
Takingsomemeasurementsfromthevise,transferthis
informationtoapaperpattern.Thecoversshouldwrap
partwayaroundthejawstoholdthemselvesinplace.It
maytakeacoupleofadjustmentstoarriveatapatternthat
willfitwell.Asheetofcardstock/coverstock,orother
thickpapermaterialwillbedurableasapattern.
Transferthepatterntothealuminumsheetwithafine
tippedmarker.Thealuminumcanbecutbyscoringwitha
utilityknifebladeandthenlightlybendingitbackand
forth.Itwillsnapoffcleanlyalongthescoremark.The
materialisthinenoughthatcurvesandinsidecornerscan
becutthisway.
Wrapthecoverastightlyaspossiblearoundthevisejaws.
ItisOKiftheyareslightlyloose.Thistypeofaluminumis
verythin,andwillwearoutaftersomeuse,sokeepthe
patterntomakemorecoversinthefuture.
Anotherhelpfulclampingdeviceisablocktoholdround
stock,suchasthreadedrod,inthevise.Thesewerequickly
fabricatedoutoftwolengthsof3/4"squareoakstock.
Theywereclampedtogetherwithastripofpapermatboard
betweenthemasaspacer(cardboardorathinstripof
woodwouldworkfine).Drillaseriesofholesincommon
sizes.Theseareveryhelpfulwhenmakingstudsfrom
threadedrod.Theyworkwonderfullytoholdthemwithout
damagingthethreads,suchaswhilefilingtheirendsflat,as
inthephotototheleft.
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scribing&cuttingstock
Thetoolstotheleftwereusedtomarkthelocationsofcuts
onthelengthsofmaterial.Theseareasteelengineer'sscale
with1/64"divisions,afelttipmarker,acarpentersawl,anda
smallsquare.Tomeasurepieceslongerthanthe6"scale,a
24"carpenterssquarewasused,hookedovertheendofthe
material.Themarkerisusedtoprovideacoloredbackground
toscribethrough.Abluemarkermayworkbetterthanablack
one,asitmayprovidebettercontrastwhenalineisscribed
throughit.Blueisalsothecolorofthetraditional
machinistsdyethatisusedforthisoperation.
Marktheareawherethecutistobelocatedwiththefelttip
marker.Thescratchawlisusedforjustthattoscratchathin,
accuratelinethroughtheareaofcolor.Thescribedline
shouldnotgodeepintothematerial,justenoughtogo
throughthemarker.Ifthemarkeriswashedoff,thescribed
lineshouldjustbarelybevisible,andbarelybefeltwitha
fingernail.
Usethesquaretoextendthescribedlineallthewayaround
thematerial.Theendofthelastlineshouldmeetupexactly
withthefirstline.Thiswillserveasacheckthatthemarksare
preciselyperpendiculartotheedges.
Withthepiececlampedinthevise,begincuttingwitha
hacksaw.Notethatthecutisjusttothesideofthescribed
line.Itjustbarelyleavesthescribedlineonthefinished
piece.Usetheedgeofyourfingerasaguidefortheblade,and
begintocutcarefullyandslowly.Keepthebladehorizontal
andonlyapplypressureontheforwardstroke.Aftercutting
about1/8"3/16"deep,removethepiece,rotateit90degrees
andmakeanothercutonthisface,alsoabout1/8"3/16"
deep.Continuethisallthewayaroundtheperimeterofthe
part,asseentothelowerleft.
Likethescribing,thelastcutshouldexactlylineupwith
whereyoubegan.Withaconsistent1/8"3/16"grooveall
thewayaroundthepart,makeafinalcutallthewaythrough.
Thegroovewillhelpguidethebladestraightthroughthe
materialonthefinalcut.Thecompletedcutshouldnowbe
perpendiculartolengthofthematerialandrequireminimal
cleanupwithafile.
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107
cuttingstockwithamitersaw
Whileperfectlyadequatecutscanbemadewithasimple
hacksaw,themethodistedious.Thelargenumberofparts
onthismachinecanbycutmuchmorequicklyand
accuratelywithasimplepowermitersaw,asshowninthe
imagetotheleft.
Acommonfinetoothedcarbidetippedbladedesignedfor
woodcanbeused,however,amuchfinerfinishcanbe
achievedwithabladedesignedspecificallyforusein
aluminum.Thesebladeshaveanegativecuttingrakeangle.
Thedifferenceincutqualitybetweenawoodbladeandan
aluminumbladecanbeseenintheimagetotheright.The
parttotherearwascutwiththealuminumblade.
ThebladeusedhereiswasmadebyOnsrud,andwas
purchaseddirectlythroughthemanufacturerviatheirebay
storefront.Bestperformancewiththistypeofbladecanbe
achievedwithabladelubricant,suchasthewaxstickinthe
imagetotheright.Carefullylowerthespinningbladeonto
thewaxstickpriortomakingacut,tocoatitsteeth.
Whenmakingacut,besurethattheworkissecurely
clampedtothesaw.Pullthesawtriggerandallowthe
bladetocometofullspeed.Thebladeusedhereisquite
heavy,anditsquicklyacceleratingmasswillmovethesaw
significantlyifitisnotclampedsecurelytoasurface.
Gentlylowerthebladeintoandthroughtheworkpiece.
Releasethetriggerandallowthebladetocometoafull
stopBEFOREraisingitbackupthroughthecutpart.This
willgreatlyminimizethechanceofkickbackorhavingthe
bladecatchanedgeofthepart.
ONLYusethismethodifyouarecomfortablewiththe
equipment.Wearfullsafetygearandneverplaceanypartof
yourbodydirectlyinlinewiththespinningblade.
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labelingparts
Thealuminumpartscanallbecuteitherbyhandor
withamitersaw.Itisrecommendedtocutthecutthe
steelpartstolengthwithahacksaw,orothercold
methodsuchasametalcuttingbandsawwith
coolant.Donotuseanymethodthatwillintroduce
significantheat,suchasabrasivecuttingblades,as
heatmaycausesmallwarpingofthematerial.
Cutallofthealuminumandsteelpartstolength.To
stayorganized,aseachpartiscuttolengthwritethe
dimensionofitslengthonitwithamarker.Itisalso
helpfultowritethepartnumberorname.
Afterallofthemetalpartsarecuttoroughlength,filethe
endscleanifnecessary.Clampthepieceinthevisewith
theendfaceup,usingthesoftjawcovers,andcarefully
filetheendfacesflat.Becarefultokeepthefile
horizontal,andonlyfiledeepenoughtogetbelowthe
marksfromthesawblade.Itisbettertoerronhavinga
partslightlytoolongthantooshort,sobesurenottofile
toofarevenifitmeansleavinganendfacewithsomefine
sawmarksremaining.Fileaslightchamferoneachend
faceedgetoremoveanysharpburrs.
Keepthepartsorganized.Therewillbealotof
partsintotal,sokeeporganizedwithsomesortof
system,sothatpiecesdon'tbecomemixedup.
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109
holelayout
Tomarkthelocationsoftheholestobedrilledontheparts,a
6"engineersscale,felttipmarker,circletemplate,thescratch
awl,andafinetipfeltpenwereused.Adisposabletechnical
peninan.03tipwidthworkswell.Acarpenterssquarecanbe
usedonthelongerparts.Itensuresthatmeasurementsare
accuratelymadefromtheendface.Becautiousifusinga
carpenterssquare.Whilesomeedgesaremarkedintraditional
1/8",1/16"or1/32"divisions,othersmaybemarkedin
1/10"or1/12".Thiscancauseseriouserrorsinmarkingifnot
careful.
Usethefelttipmarkertocolorazoneonthepartwherethe
centerlineoftheholeislocated.Measureandscribeafineline
acrossthepartatthecenteroftheholelocation.Alsoscribea
lineatthesidetosidedistancetocreateascribedcrosshairsat
eachholelocation.Scribingthelinethatrunsparalleltothe
lengthofthealuminumpartsmaybedifficultduetomarksin
thesurfacefromtheextrusionprocess.Thesemightpullthe
awlintothemandcreateaninaccurateline.Ifthishappens,
colorbackoveranyinaccuratescribelinesandtryrescribing.
Usethecircletemplate,lineduptothescribedcrosshairs,to
drawtheoutlineoftheholewiththefinefelttippen.Also,
writethediameteroftheholedirectlyontheparttoavoid
havingtoconsultthedrawingslatertoredeterminethehole
size.Witheverythingclearlymarkedonthepart,littlethinking
willberequiredwhendrillingtheholes.Markthetappedholes
inasimilarmanner.
Adrillpressishighlyrecommendedtoachievethenecessary
accuracywhendrillingholes.Itisalmostindispensable,and
theycanbepurchasedquiteinexpensively.Makesureithas
enoughquilltravelandthroatclearancetohandleallofthe
drillingrequirements.Adrillpressviseofsomesortisalso
veryhelpful.Thedrillpressusedherewasaveryinexpensive
homeownersquality,equippedwithacompoundcrossslide
vise.Takesometimetoadjustthedrillpresssothatthetable
isexactlyperpendiculartothequill.
Whendrilling,especiallyonthealuminumparts,alwaysusea
propercuttingfluid.Drillingaluminumdrywillquicklydestroy
thedrillbit.
Thedrillbititselfcanbeusedtoaccuratelyclampthepart.
Extendthequilldownalongsidethepart.Pushitupagainst
thedrillbitwhileclampingitinplace.Thiswillensurethatit
isparalleltothelengthofthebitandquilltravel.
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110
tappingholes
Clampthepartstobetappedfirmlyinavise(usethesoft
jawcovers,unlikewhatisshownhere).Securethetapinto
thetaphandleandstartitintothehole.Besuretouse
plentyoftappingfluidthatisdesignedfortapping
aluminum.WD40canbeusedifitisnotavailable.Using
tappingfluidiscrucial.Tapswillnotlastlongwhen
tappingaluminumwithoutit,especiallythesmallersizes,
possiblynotevenmakingitthroughthefirsthole.
Ifyouhavenevertappedaholebefore,itishighlysuggested
todoatrialrunonanextrapieceofaluminum.Usethe
properlysizeddrillbitanddrillafewholestobetapped
1/420.Itisworthgettingusedtotheexperienceona
scrappiece,astapscanbequitefragile.Anysideloading
canimmediatelysnapthemoff,ascanexcessivechip
loadingintheflutes.Abrokentapcanbenearly
impossibletoremovefromthepartwithoutspecialized
equipment,soatapbrokenoffinafinalpartwillmost
likelyrequirestartingcompletelyoverwithanewpiece.
Bettertobreakatapinapieceofscrap.Thatsaid,withthe
propertechniqueandagoodlubricant,tappingholesin
aluminumisquickandeasy.Alsorecommendedis
tappingallofthe1/420holesfirst,togetcomfortablewith
thetechnique,beforeattemptingthe1032holes.The
smallertapsizeislessforgivingoferrorandwillbreak
mucheasier.
Turnthetapintotheholeandcheckthealignmentasit
startstobite.Lookatthetapfromboththefrontandthe
sidetomakesureitisexactlyperpendicularlytothepart.
Theonlyopportunitytomakeanycorrectionisduringthis
firstpartialturnofthetap.Eventhen,theamountof
correctionpossibleisminor.Tapsareverybrittleand
cannotwithstandANYsideloading.Asthetapisthreaded
intothehole,stopeveryturnorsoandbackthetapouta
partialturntobreakthechipsbeforegoingdeeper.
Whenthetapcomesoutofthebacksideofthehole,clean
thechipsoffofitwithaspraylubricantbeforethreadingit
backoutofthehole.
Withthetapremoved,cleanitthoroughlyofallchips
beforestartingthenexthole.
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stitchdrilling
Thereareafewlargediameterholesthatneedtobecut,as
wellassomeuniqueshapescutfromplate.Whilethelarge
diameterholescanbecutwithaholesawifitisavailable,the
followingtechnique,calledstitchdrilling,canbeusedforany
ofthesecuts.Aseriesofcloselyspacedholes,thatslightly
overlap,aredrilledalongtheedgeofthecutline.Thiswill
removeaplugofmaterial.Finalshapingcanthenbedone
withahandfile.Thiscanbeusedbothforpartscutfromthin
(3/16")stock,aswellasoutofconsiderablythickerplate.
Thebestdiameterofdrillbittouseforthisisacompromise,
andwillrequiresomejudgment.Thesmallerdiameterdrillbit
used,thelessmaterialthatwillneedtoberemovedwiththe
fileduringcleanup.However,thesmallerthediameterthebit,
themoredifficultitistodrillsequentialholesthatbarely
overlap.Alargerdiameterbitmakesitmucheasierto
accomplishthisoverlap,butrequiresmorematerialremoval
withthefile,hencerequiringmoretime.Generally,the
smallestbitthatwilleasilyallowdrillingholesthatoverlapthe
previousonesshouldbeused.Abitaround1/4"dia.will
provideagoodstartingpoint.Ifindoubt,usealargerbit.
Clampthepartinaviseandfinishfiletothefinalsize.
Intheexampletotheright,alargeroundholeisbeingcut.A
circletemplatewasusedtodrawaconcentriccirclethatis
smallerindiameterthanthedesiredholebythediameterof
thedrillbitbeingusing.Forexample:fora1.5"dia.finishhole
size,usinga1/4"drillbit,a1.25"circlewasdrawn.Aseriesof
slightlyoverlapping1/4"holeswerethendrawnusingthecircle
temple,placingtheircenterpointsontheinnercircle.These
weresimplyspacedbyeye.Thecenterpointofeach1/4"hole
wascenterpunched.Theholesweredrilled,removingaplugof
materialasshown.Thesameprocesscanbeusedforthicker
stock,asseenintheimagestotheleft.Bothpartswerefinished
tofinalsizebyhandfiling.Iftheholesdonotcompletely
overlap,itmaybedifficulttoremovethewastematerial.Acold
chiselmaybeusedtocutanyremainingwebs.Thewasteonthe
parttotheleftwascutoffwithahacksaw.
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holesaw
Thereareseveralwoodcomponentswithlargeholes,whichare
easiesttocutwithaholesaw.Useoftheholesawisdiscussed
onpage91.Likewise,thereareseveralaluminumcomponents
whichmayalsobecutusingthesametwosizesofholesaws(1
1/4"and11/2".)Useofaholesawwillbeespeciallyhelpful
whenfabricatingtheZmotormounts.Thesetwopartshavea
concaveradiusgroovecutoutoftheirinnerfaces,whichcan
easilybecutwiththe11/4"holesaw.Thesawmustbeofthe
typethatcanbeusedtocutmetal.
Theeasiestwaytoaccomplishthiscutisbyclampingthetwo
partstogether,witha3/4"spacerbetweenthem,anddrillingas
oneunit.Inthetoptwoimages,thepartsareclampedinabench
visetomeasureandmarktheholelocation.
Aswhenusingtheholesawinwood,predrillingsmallerholes
forchipclearancewillimprovethesmoothnessofthecut.
Drilltheseholesjusttotheinsideofthelargerholethatwill
becut.Anadditionalholecanbedrilledatthecenter,toact
asaguideforthepilotdrillinthecenteroftheholesaw.This
isoptional,andwasnotdonehere.
Clamptheworkinthedrillpressviseandcarefullyalignthe
holesawtothemarkedcircle.Usealowspindlespeedonthe
drillpress.UseacuttingfluidorWD40whilemakingthecut.
Thecompletedpartswithneatlymatchedgroovesare
showntotheright.Nofurtherfinishingwasrequired.
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carriagematchdrilling
Thecarriageassemblyhasseveralpartsthatrequireholes
drilledwhiletheyareclampedinalignmentwitheach
other.Gatherthefollowingfivepartstogether,asseenin
theimagetotheleft:
#13carriageblockrearlower
#16carriageblockfrontright
#17carriageblockfrontleft
#19lowerspacers
Beginwithlowerrearblock,onelowerspacer,andeitherof
thefrontblocks.Asseeninthetopandmiddleimagesto
theright,usinganaccuratesquare,scribeguidelinesthat
correspondtowheretheedgesofthespacerswillbewhen
thepartsareassembled.Clampthe3partstogetherwitha
5/16bolt,asseeninthelowerleftimage.Usethescribed
linesasguidestokeepthefrontandlowerblockssquareto
eachother,andcenteredproperly.Doublecheckthatthey
aresquaretoeachotherandfullytightenthebolts.Triple
checkthatleftandlowerblocksaresquaretoeachother.
Fliptheassemblyoverandclampitintoaviseonthedrill
presstable.Checkagainthatthepartsaresquaretoeach
other.Inserta3/16drillbitintothechuck.Lowerthequill
nexttothepartstomakesurethatthedrillpressspindleis
paralleltotheedgesoftheparts.Thisdrillingoperationwill
begoingthroughthethicknessofall3parts,sothedrillneeds
togoasstraightthroughthemaspossible.Carefullyalignthe
drillbitwiththeexistingholesofthelowercarriageblockand
drilldownthroughtheothertwoparts.Alignthebitcarefully
sothattheexistingholesarenotreamedoutlarger.
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carriagerollpins
Takethepartsoutoftheviseanddisassemblethem.Mark
themfirstsothattheycanbeputbacktogetherwiththe
spacerintheexactsameorientation.Carefullycleanthe
partsofanyoils,cuttingfluids,etc..Withahammer,drive
two3/16x2rollpinsdownthroughthe3partstore
assemble.Withnobolt,thejointconnectionbetweenthe
partsshouldhavenoperceptibleplayormovement.
Repeattheprocedurewiththerightsideparts.For
accuratealignment,usethesquareaswellastaking
multiplemeasurementsbetweentheleftandrightside
carriageblockstomakesuretheyareexactlyparallel.
Thisdistanceshouldmeasure2.625".
Drivetherollpinsdownthroughthesecondjoint,asseenin
theimagetotheleft.Withnoboltsinstalled,asseentothe
right,theassemblyshouldbestrongandrigid,withno
play.The5/16"boltswillbereinstalledduringalater
assemblystep,togiveadditionalstrengthtothejoints.
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cuttingroutermounts
Therouterclampsarefabricatedfromthickaluminumbar
stock,andhaveacomplexseriesofcurvedcuts.Whileametal
cuttingbandsawwouldbeahelpfultooltomakethesecuts,the
pieceshereweremadeusingthestitchdrillingtechnique
outlinedonpage111.Thebasicprincipleisthesame:drillinga
closelyspacedseriesofholesandthenhandfilingtofinalsize.
Duetothethicknessofthematerial,itisbeneficialtousethe
smallestpracticalsizeofdrillbitdiameter,asalargerbitwill
leavemorematerialtoberemovedacrossthefaceofthepart
thickness.A1/4drillbitwasusedinthesephotos.
Asthegeometryofthepartsisrelativelycomplex,itmaybe
helpfultoprintthedrawingsheetsandcutthemoutforuseas
patterns.Ifprintingpatterns,usedurableheavypaperorcard
stock.Afterprinting,measurethelongerdimensionstocheck
thatthesheethasaccuratelyprintedtoscale.Ifnot,adjustthe
printerscalesetting.Unfortunately,printerscaleerrorisoften
lessthan1%,whichisenoughtocauseaslightinaccuracybut
notenoughtobeabletocorrectthroughtheprinterdriver.
Carefullycutthepatternoutwithasharprazorblade.
Thepartsshownherewerelaidoutdirectlyonthestock,
withoutaidofpaperpatterns.Thematchingcomponents
(mountandclamp)weremarkedtogetherasoneunit.Todoso,
awoodblockofthecorrectthicknesswasclampedbetween
them.Filletcurvesweremarkedwithacircletemplateandfine
felttippen.Asseenintheimagetotheleft,thesewerethefirst
holestobedrilledinthestock.Afterdrillingtheseholes,the
closelyspacedstitchholeswereplacedalongtherestofthe
partoutline,asseenintheimagetotheright.
Ahacksawwasusedtoremovetheexcessmaterial.Onthe
mountcomponent,aholesawwasusedtodrillclosetothe
surfacesthatwillcontacttherouterbody.Thiscanbeseenin
theimagetotheright.Whiletheholesawisasmaller
diameterthantherouterbody,itcancutmuchclosertothe
layoutline,andwillrequirelessfilingthanaseriesofsmall
diameterstitchholes.Afterremovingthebulkofthestock,as
seeninthesephotos,thepartswerehandfiledtoremovethe
remainingmaterial.
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beltclamps
Thedrivebeltsaresecuredwithfabricatedclampsthathave
correspondinggroovescutintothem.Thiscanbeachieved
withasimplehacksawandsomepatience.Nofilingwasdone
inanyofthesephotos,thiswasalldonewithjustthe
hacksaw.
Holdalengthofthebeltsecurelyonthepieceofstocktobe
marked.Scribeshortmarksthatalignwiththewidthofthe
rootofthebeltteeth.Asyoumovealongthebeltmarking
teeth,moveyourheadaswell.Itisimportantthatyouare
lookingexactlystraightonatthebeltwhilemarkingtoavoid
parallaxerror.
Withtheteethwidthsmarked,useasquaretoextendthe
scribelinesacrossthewidthofthestock.Withthestock
firmlyclampedinthevise,slowlybegintousethehacksawto
cutoutthegrooves.Keepthesawashorizontalaspossible
anduseafingerortwoasaguideagainstwhichthesideof
thebladerests.Thinkofthesawbladeasalongnarrowfile.
Tiltthesawtothesidetowidentheslotifnecessary.
Alternatively,installtwobladesinthehacksawhandle.This
willeffectivelycreateawiderbladethatmaymoreclosely
matchthewidthofthegrooves.
Whenthebeltisinstalledonthemachine,thesepartsare
exertingclampingforceagainstthebelt,thereforethedepth
ofthegroovesdonotneedtobethefulltooththickness.
Moreimportantisthatthecentertocenterspacingofthe
groovesmatchesthebelt.Aslongasthereissomesmall
amountofgrooveitwillpreventanybeltslippageonce
clampedtogether.Cuttingthesegroovesismucheasierthan
itmayseem,andtheworkprogressesquickly.
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installingstudsAssembly
Withallofthe1/4threadedstudscuttolength,gatherallof
themetalpartstogether.Locateallofthepartsthatwillhave
studsthreadedintothem.Makesurethatthethreadsonall
thepartsarecleanandfreeofanyoils,tappingfluids,etc.
Cleanthepartswithadegreaserifnecessary.Cottonswabs
canbeusedtoreachintotheholes.
Thestudswillbeadheredintotheirholeswithathreadlocking
compoundsothattheywillnotturnwhennutsaretightened
ontothem.Sinceitcanbeverydifficulttoremovethesestuds
oncetheyarebondedinplace,itishighlyadvisabletodoatrial
assemblyofallpartsthatareheldtogetherwithstuds.This
willallowcheckingthatallstudlengthsarecorrect.Usingplain
nutscanhelpwithatrialassembly,asusingthenyloninsert
locknutswillsimplycausethestudtoturndeeperintothe
part.Followingtheexplodedviewdrawingsonpages3033,
threadthecorrectstudsintotheparts.Thestudlengthsare
calculatedfor1/2"threadengagementintotheparts.Withall
ofthestudstemporarilyinplace,followtherelevantdirections
onthefollowingpagestocompleteatrialassemblyofmating
parts.Ifallseemstoassembletogethercorrectly,disassemble
theparts,keepingstudlengthsorganized.
Applyacoupleofdropsofpermanentthreadlocking
compoundtotheendofthestud.Asmallamountis
sufficient.Thetipofthetubecanbeusedtospreadthe
compoundaroundthecircumferenceofthestud.Threadthe
studintotheholetotherequireddepth.Setthepartsaside
toletthemcure.Leavethemundisturbedforafulldaybefore
beginninganyassembly.
Ifanyofthestudsneedtoberemoved,thepermanent
threadlockingcompoundrequirestheapplicationofheatto
softenit.Heatthepartinanovenat400degreesF,orusea
propanetorchappliedtothepart.Thestudshouldnowbe
abletoremovedwithapairoflockingpliers.Aftercooling,
chasethethreadsinthealuminumpartwithataptoremove
threadlockingcompoundresiduebeforeinstallinganewstud.
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gantryrailAssembly
BeginassemblyofthemetalpartsbyattachingtheYrail(part#
11) tothegantrytube(part#02).Assembleusing(7)1/420x
1/2"socketheadcapscrewsandlockwashers.Thecapscrews
needtohavefullthreadengagementintherail,yetnot
protrudebeyonditsouterfaceortheymaystrikethecarriage
asitslides.Achievingthisproperengagementmayrequiring
adjustmentbystackingseverallockwasherstogether.Here,
twowereusedundertheheadofeachscrew.
Useahexkeythatislongenoughtofeedthecapscrews
throughthe1/2"holesinthebackfaceofthegantrytube.
Itmaybeeasiertodothisifthefrontofthegantrytubeis
orientedfacingup.Thisway,gravityisholdingthecap
screwonthehexkeyasitisfedupthroughtheholes.
Getall7ofthescrewsthreadedintotherail,butdonot
tightenfully.Tightenthetwoouteronesuntiltheyarejust
snugenoughthattherailcanstillbemovedaroundwhen
pressureisapplied.Checktomakesurethethreadsdonot
protrudebeyondthefaceoftherail.
Useascaleandmeasurebothtopandbottom,andateachend
oftherailtomakesureitisexactlycenteredonthegantry
tube.Whenitiscentered,tightenallofthescrewsdown
fully.Asseenintheimagetotheleft,thegantrytubeshould
extendbeyondtherailateachendby.75".
Washers
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leftgantryAssembly
Asperthediagramtotheleft,andimagetotheright:
Threadanyloninsertlocknut,withtwoflatwashersaboveit,
ontoeachofthestudsinpart#03,markedgantrylefttop.
Threadthenutsnearlytothetop,leavingabout3/16"ofaninch
betweenthewasherandthepart.Threadanothernutontoeach
stud,thistimewiththenyloninsertgoingonfirst.Todothis,if
maybenecessarytothreadthenutsonintheconventional
directionfirst,perhapsevenacoupleoftimes,sothatthestud
formsthreadsintothenyloninsert.Evenhavingdonethis,it
maybedifficulttogetthenutsthreadedonstraight.Usecaution
anddonotforcethenutontothestudifitisnotgoingon
straight.Threadthesenutsupthestudsothattheyareabout
1/2"belowthefirstset.Slideaflatwasherupeachstudsothat
itisagainsttheinvertednuts.
Thisassemblyshouldnowslideintotheslotsontheleft
sideofthegantry,andlookliketheimagetotheright.
Makesurethatthecorrectendofthepartisfacingforward.
Dependingonthetypeofwashersbeingused,andtheir
particularoutsidediameter,itmaybenecessarytofileaflat
onthefourwashersthatareinsidethegantrytube,asseen
inthetoprightimage.SAEdimensionwashersshouldfit
withoutmodification.USSdimensionwashersarelargerin
diameter.
Usingasquare,aligntheinsertedpartsothatitisperpendicularto
thegantryandtightagainsttheendoftheYrail.Tightenthetop
setofnuts,beingcarefultokeepeverythingperpendicular.
Next,threadtheinvertednutsbackdownthestudsothattheyare
justputtingaverylightpressureagainstthebottominsidefaceof
thegantrytube.Thepurposeofthesenutsistokeepthegantry
tubefrombeingcrushedunderthepressureoftighteningthe
bottompart.
Withthelowernutsincontactwiththeinsideofthegantrytube,
slidetwowashersandpart#01(gantrybottom),upthestuds.
Washers
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rightgantryAssembly
WASHERS
Usingthesquaretomakesurepart#01(gantrybottom)isalso
perpendiculartothegantry,installanothersetofflatwashersand
locknutstoholditinplace.Tightensecurely.Theassembly
shouldlookliketheimagetotheleft.Notethedrawingsand
imagescarefullyfortheplacementofthefourwashersbetween
thegantrytubeandtheotherparts.Thesearenecessaryfor
correctspacing.
Usingthesameprocedure,andsequenceofnutsandwashers,
installparts#01(gantrybottom)and#04(gantryrighttop)onthe
rightendofthegantrytube.Parts#05(gantryspacer)and#06
(gantryouterright)willbeinstallednext.Beforeinstallationof
parts#5and6,threadtwo1032x.75setscrewsintotheholesas
seenintheimagetotheright.
Notethatpart#06(gantryouterright)isnotquite
symmetricalanditispossibletoaccidentallyinstallitupside
down.Wheninstalledinthecorrectorientation,thevertical
holeateachendshouldalignexactlyacrosstoasimilarsetof
holesinpart#04.Withthesepartsinthecorrectorientation,
installwashersandnutsontothestudsandtightentosecure
them.Allthreeofthetoppartsshouldbeflushacrosstheir
topfaces.
Thegantryassemblyshouldlookliketheimagetotheleft.
Nextinstallparts#07and#08(Ymotormounts)asshown
totheright.Notethatthesepartsaredifferent.Theholes
forthemotorattachmentareoffesttotheinside.Closely
lookattheimageandtheexplodedviewdrawingtonote
whichsidetheyface.Ifindoubt,holdamotoruptothe
mountstomakesuretheholesalign.
Installawasherandnutoneachmotormountstud.Donot
tightenthendownfully.Tightenthenutsjusttothepoint
wherethemountscanbemovedaroundbyhand.
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carriageblocksAssembly
Locatethecarriagepartsasseenintheimagetotheright.They
areparts:
#12carriageblockrearupper
#18upperspacers
thesubassemblyfrompage113(parts#13,#16,#17,#19)
(4)5/16x3grade8bolts,nuts,andwashers.
Beginwiththesubassemblythatiscurrentlyheldtogether
onlywithrollpins.Asseenintheimagetotheright,install
twobolts,withwashersandnuts.Uselockwashersifthenuts
arenotlocknuts.
Installtheupperrearcarriageblock(part#12)andthetwo
upperspacers(part#18)asseenintheimagetotheleft.
Withthenutslightlysnug,measurebetweeneachendof
parts#12and#13toensurethattheyareexactlyparallel.
Thisdistanceshouldmeasure2.625".Adjustasnecessary.
Whensatisfiedthattheyareparallel,tightenthetoptwo
boltsfully.Ifatorquewrenchisavailable,tightenallfour
boltsto25lb/ft.Doublecheckparallelalignmenttoensure
partshavenotmovedduringtightening.
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carriageassembly
Organizethefourbearingblockstobeattachedtothe
carriageassembly.Notethatone(part#15)hasastud
installedforlaterinstallationoftheYbeltclamp.This
bearingblockisinstalledinthetopposition.Theother
threebearingblocks(part#14)areidentical.
Usingtheexplodedviewdrawingonpage31,andthe
imagesonthispage,installthefourbearingblocksintheir
correctorientations.
Next,installtheZmotormounts(parts#20and#21)asshownin
theimagestotheleftandright.Useasquaretopositionthem
perpendiculartothecarriage.Takecaretosetthemassquare
aspossible,asanyerrorwilllatercausemisalignmentoftheZ
axisleadscrew.Notethatthenutsareveryclosetogether,and
thismayprohibituseofwashers.Theyarealsocloseenough
togetherthattighteningthefirstnutsoitsflatisfacingthe
secondnutwillgivemoreworkingspaceforawrench.
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Zaxisrailassembly
LocatetheZaxispartsasseenintheimagetotheright.They
areparts:
#24zrail
#25zrailblock
#26nutplateblock
Assemblethepartstogetherasseentotheright.Install
nutsonthetopandbottomstudsoftheZrail.Donot
tightenthenutsholdingthenutplateblockatthistime.
Withthetopandbottomnutslightlysnug,adjusttheZrail
blocksothatitisexactlycenteredonthewidthoftheZrail.
Takemultiplemeasurementsoneachside,andtopand
bottom.Whencentered,tightenthetwoouternuts.
Threadthenutsholdingthenutplateblocksothattheyare
notquitesnugagainstit.
1032setscrew
5/16locknut
washer
bearing
5/1618x11/2"bolt
Notethatinsomelocations
thisbolthasamodifiedhead.
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bearinginstallation
Thenextstepistopopulatethegantryandcarriagewith
bearings.Mostofthebearingsareattachedinthe
configurationofbolt,bearing,washers,andnutthatisshow
intheaboveleftdiagram.Thissequenceofpartsisalso
seenintheimagestotheright.
Aseachbearingisinstalled,threadthelocknutonfar
enoughthatthereisjustaverysmallamountofclearance
betweenthewashersandthepart.Thebearingshouldjust
beabletoslideslightlyalongthefaceofthepart,butnot
rockorfeelloose.
NOTE:Inadditiontothisseriesofphotos,
refertotheexplodeddrawingonpage32
thatdepictsthebearinglocations.Itis
sometimesdifficulttohaveoneviewclearly
showallofthebearinglocationsinagiven
step,sothisdrawingmayhelptoclarify.
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gantrybearings
Beginbyinstallingthefourbearingsintheleftendofthe
gantry,thatareshownintheimagestotheleftandright.
Notethatthelowerbearingsuseboltswithmodifiedheads
forclearance.Thesearecircledintheimagetotheright.
Theleftendofthegantryalsousestwobearingsasanidler
bearingforthebeltdrive.Thesecanalsobeinstalledduring
thisstep.Usea5/1618x2.5"longhexheadboltorsocket
headcapscrew.Twofenderwashersareusedasflanges,
andashortstackofstandardflatwashersareusedas
spacers,toachievethecorrectheight.Wheninstalled,the
undersideofthetopfenderwashershouldbe1"fromthe
topfaceoftheuppergantryblock.
Therightendofthegantryusesfourbearingsinstalledinthe
samepositionsastheleftend.Inaddition,therearefour
morebearingspositionedfromtheunderside,asseeninthe
leftimage.Therightendofthegantryhasatotalofeight
bearingsinstalled.
Thelowerbearingsontherightendofthegantryalsouse
boltswithmodifiedheads.Theyarecircledintheimageto
theleft.
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carriagebearings
Atthelocationofeachofthebearingsthathasbeen
installedonthecarriage,threadasetscrewintothehole
thatisperpendiculartoit.Fornow,justthreadtheseina
fewturns,sothattheydonotfallout.
Thefourbearingblocks(parts#14and15)havealonger
boltthatgoesthroughthem,holdingabearingoneither
sideofthealuminumblock.Thebearingassembly
sequenceisseenintheimagetotheleft.Slideonebearing
ontothesocketheadcapscrew,andthenonewasher.Note
thatthereisnowasherbetweentheheadofthesocket
headcapscrew(5/1618x3")andthebearing.Insertthis
throughthebearingblock.Nextslideawasher,bearing,
anotherwasher,andthenthelocknut.
Installallofthebearingsontothecarriageassembly.Studythe
imagesonthispage,andtheillustrationonpage32,forthe
positionsofallbearings.Thisstepwillbeinstallingatotalof
24bearingsonthecarriageassembly.
Notethatfourbearinglocationsrequiretheuseofmodified
boltswiththinnedheads.Twoofthesearecircledinredinthe
lowerrightphoto.Theothertwoareobscuredinthesephotos,
butareinthesamepositionsontheothersideofthecarriage.
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carriageinstallationongantry
Measuretheoutsidedistanceofthelowergantryblocks,as
seenintheleftandrightimages.Itshouldmeasure24".
Thedimensioncanbeadjustedbyrepositioningthe
componentsoneitherend.Bringingthemclosertogether
mayrequiretrimmingthelengthoftheYrailslightly.
Beforemakinganyadjustments,consultthemeasurement
ofthebasethatwastakenonpage99.Forthebestfit,the
gantrymeasurementtakehereshouldbeexactly1"less
thanthemeasurementofthebasetakenonpage99.
Afterassuringthatthecorrect1"differencebetweenthe
twomeasurementscanbeachieved,removethe
componentsfromtheleftendofthegantry.Fullyremove
thelowerpiece.Slightlyloosentheremainingnuts,and
theassemblywillslideoutoftheslotsinthegantrytube.
Slidethecarriageassemblyontothegantry,feedingtheYrail
betweenthebearings.Thereshouldbeenoughclearance
betweenthebearingsandtherailthatitslidesoneasily.If
thebearingsdonotmovefarenoughaparttoallowthe
carriagetoslideontotherail,stopandinvestigatewhy.If
therewasinaccuracyindrillingholes,theremaynotbethe
properrangeofadjustabilityforthebearings.Ifthishappens,
lookcloselytodeterminewhichbearingsneedtobeableto
slidefurtherawayfromtherail.Removethemfromthe
carriageassembly.Theholescanthencarefullybefiledto
elongatethem,givingmoreadjustmentrange.
Reinstallthecomponentsontheleftendofthegantry.Usea
squaretoensuretheyareperpendiculartothegantry,and
remeasurethedimensiontakenatthetopofthispage.
Becarefulinhandlingthefinalgantryassembly,asthe
carriagewillslideveryeasilyandhassignificantmass,which
caneasilyleadtosmashedfingers.
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gantrybeltdrive
Asseenintheimagestotheleftandright,installa10tooth
timingbeltpulleyontotheshaftofasteppermotor.A
measurementof7/8"fromthefaceofthemotortothe
outerpulleyflangeshouldresultinacorrectbeltalignment.
Installthemotorwithfour1032x1"socketheadcap
screws,ormachinescrews.Placewashersbetweenthe
motormountsandthemotor,asshowntotheleft,toraise
theroundbossontheendofthemotorclearofthemounts.
Twoflatwashersweresufficienthereforclearance.
Tightenthemotortothemotormounts.
Hookthe250toothbeltaroundtheleftidlerpulley.Remove
themotor,stillattachedtothemounts,fromthegantryand
hooktheotherendofthebeltaroundthemotorpulley.The
motorandmountscannowbeloweredbackdowninto
position,andthenutsreinstalledonthemountstuds.
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gantrybeltdrive
Tightenthenutsonthemotormountstudssothatthey
arenotquitesnug.Insertahexkeythroughtheholesas
shownintheimagetotheright,sothatitengageswiththe
setscrews.Tightenthesetscrews,workingalternatelyfrom
onetotheother,totensionthebelt.
Whenthebeltisatsufficienttension,fullytightenthenuts
onthemountstuds.Becarefultonotovertightenthebelt,
asthesetscrewsarecapableofapplyingsignificantpressure.
InstalltheYbeltclampasshownintheimagetotheright.
Beforetightening,itisimportanttoinstallasmallspacer
behindthetopsideoftheclamp.Thisservestohelpthe
clampputevenpressureagainstthefullwidthofthebelt.
Thespaceriscircledinred.Thespacerusedherewascut
frompapermatboardandmeasuresslightlymorethan
1/16"thick.
Notethattheclearancebetweenthestudandtheinside
ofthebeltisveryclose.Ifcontactwiththebeltoccurs,
especiallyatthemotorendofcarriagetravel,itmaybe
necessarytoshortenthestudslightly.Dependingon
tolerances,itmayevenbenecessarytotrimthethickness
ofthenut,orthethicknessofthebeltclamp.
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Zaxisassembly
NexttobeinstalledaretheZaxismotorandZcable
plate(part#22).Withtwolocknutsandwashers,
installthestudintothecableplateasseenintheimage
totheleft.
InstallthemotorandcableplatetotheZmotormounts
with1032x1.75"socketheadcapscrewsormachine
screws.Theassemblyshouldlookliketheimages
shownonthispage.
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Zaxisassembly
SlidetheZrailassemblyintothecarriagebearingsfrom
thebottom.Itmaybeeasiesttoworkbylayingthe
gantryassemblyonitsback.
Assembletheantibacklashnuttothebottomofthenut
plate(part#27)withfour#4machinescrewsandnuts,as
seenintheimagetotheright.Threadtheleadscrew
abouthalfwayintotheantibacklashnut.
Threadthemotorcouplerontothetopoftheleadscrew.
Threaditonsothattheendoftheleadscrewisaligned
withtheslotthatiscutthroughthecoupler.The
assemblyshouldlooklikethephotototheleft.
IfusingamotorcouplermadeofDelrinplastic,anadditional
setscrewshouldbeadded,asshownintheimagetotheleft.
Drillandtapwith#1032threadsforthissetscrew.Thiscan
thenbetightenedagainsttheflatonthemotorshaftfora
moresecureconnection.
NOTE:
Seetheaddendumonpage171foranalternativelead
screwassemblythatincludestheadditionofthrust
bearing.Followingtheprocedureintheaddendumis
HIGHLYRECOMMENDED.
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Zaxisassembly
Positiontheleadscrewassemblyasintheimagetotheright,
sothatthemotorcouplerisalignedwiththemotorshaft.
Slidethecouplerontotheshaftandtightenitsscrewsto
secureittotheshaft.
LettheZrailassemblyslidedownsothatthestudsonthe
bottomofthenutplateblockgothroughtheholesinthe
nutplate.
Installtwolocknutsasseenintheimagetotheright.
Threadthenutsonsothattheyarenotquitetouchingthe
nutplate.Notethatthestudsareclosetogether,which
maypreventtheuseofwashers.
NOTE:
Seetheaddendumonpage171foranalternative
leadscrewassemblythatincludestheadditionof
thrustbearing.Followingtheprocedureinthe
addendumisHIGHLYRECOMMENDED.
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Xaxisrailinstallation
ThenextstepwillbetoinstalltheXrailstothemachine
base.Beginwiththefourrailpartsshownintheimageto
theright:
part#28Xrails
part#29Xrailangleleft
part#30Xrailangleright
Assembletherailstotheangleswithhexhead1/420x
1/2"bolts.Useasinglelockwasherbeneaththeheadof
eachbolt.Asseeninthelowerleftphoto,thethreadswill
protrudetoofarbeyondthefaceoftherails.LiketheYrail
thatisattachedtothegantry,thethreadsmustnot
protrudebeyondtherailface.Donotuseadditional
washersbeneaththeheadsoftheboltstocorrectthis.The
threadlengthoftheboltsmustbeshortened.Thiscanbe
donebeforeinsertingthebolts,oraswasdonehere,
carefullygrounddownafterassemblywithadiscgrinder.
Withtheboltsappropriatelyshortened,adjusttherailssothat
theirloweredgeisflushwiththebottomfaceoftheangles.
Tightentheboltssotheyaresnugtight.Donotfullytighten,as
furtheradjustmentoftherailpositionswillbedonelater.
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Xrails
Usingfour#1032x1"socketheadcapscrews,ormachine
screws,installtheXsteppermotor(withpulleyinstalled)
andrightplate(part#31)totherightangleandrail.Atthis
pointtherewillonlybetwoscrewssandwichingthe
assemblytogether,sousecautionwhenhandling.
NotethatthetopedgeoftheXrailangleshavebeenground
downinheight.Thiswillprovideclearanceforbearingsthat
contacttheedgesoftheXrails.
Placetheassemblyfromthestepaboveintopositiononthe
machinebase.Placetheleftplate(part32X)andleftrail/angle
assemblyintopositionontheotherside.Thecorrectpositioning
ofthesepartsiswiththerearfacesflushwiththerearfaceofthe
base,asseenintheleftimage.
Securetheplates/anglestothebasewiththelagscrewsandaflat
washerbeneatheachhead.Fullytightenthe7lagsoneachside
thatonlygothroughtheplate.Adjusttheangle/railassemblies
sothatthereis.1875"betweentheedgeoftheplateandtherear
faceoftheXrail,asshownintheimagetotheright.Measureat
frontandrearpointsalongtherailtomaintainaconsistent
.1875"overhang.Thiswillprovideaninitialadjustment.Tighten
thefrontandrearlagscrewsthatgothroughbothplateandangle
sotheyaresnug,asseenintheimagetotheright.
MeasurebetweentheinsidefacesoftheXrailsatthe
frontandrearofthemachineasshowntotheright.If
everythinghasbeenconstructedaccurately,this
dimensionshouldbe24.125".Therailsneedtobeas
parallelaspossible,soifthemeasurementsdonot
match,loosenthelagboltsslightlyandcarefullyadjust
thepositioning.Thereshouldbelessthan1/32"
discrepancybetweenthefrontandrearmeasurements.
Aimtoachieverailsthatareasparallelasyour
measuringmethodwillallow.Withtherailspositioned
parallel,installtheremaininglagscrewsandfully
tightenallofthem.
.1875"
24.125"
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gantryandpreliminaryadjustment
OncetheXrailsareparallel,attemptslidingthegantry
assemblyontotherails,asseeninthephotototheleft.
Goslowlyandcarefullywiththis.Thereislittleclearance
betweenthelowerbearingboltsandthemachinebase,
andtheboltheadscangougethesurfaceofthebaseifthe
gantryisnotslidexactlystraightontotherails.Thetight
clearancecanbeseenintheimagetotheright.
Tokeeptheboltheadsfromrubbing,apreliminaryadjustment
shouldbemadetothebearings.Thiswillkeepthegantry
centeredwithintherailsandallowittotravelsmoothlyalong
thelengthoftherails.Acompletealignmenttotherestofthe
bearingswillbeperformedlater.Beginbyadjustingthetwo
bearingscircledintherightimage.Holdsidewayspressure
againstthegantry,pushingthesetwobearingsagainstthe
faceoftheXrail.Usethesetscrewstoadjustthebearingsso
thethetwolowerbearingboltheadsclearthebasebyabout
1/16".PlaceasquarebetweentheXandYrailstocheckthat
theyareperpendiculartoeachother.Tightenthenutsto
securethebearingsthathavejustbeenadjusted.
Asseeninthemiddleleftimage,adjustthetwobearings
thatrideagainsttherearfaceoftherightXrail.Tighten
themsothatthegantryfeelsrigidlyattachedtotherail,
withnoperceptibleplay.Readjustasnecessarytogetthe
gantryatexactly90degreestotheXrails,asseentothe
left.Consulttheadjustmenttechniquesonpage161to
helpmakethisalignment.
Adjustthetwobearingscircledintheimagetotheright.
Theyshouldbesetsothatthegantryisraisedhighenough
thatthereisnointerferencebetweenanypartsasitis
pushedforwardandbackalongtherail.
Thisseriesofadjustmentsshouldallowthegantryto
smoothlyroll.
90
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Xbeltassembly
Whenthegantryisrollingsmoothly,withnointerference
atanypointalongitstravel,installtheXbeltcomponents.
BeginwiththeXbeltpulleyadjuster(part#33).Installthe
hexheadboltintothethreadedhole.Thisisan
uncommonsizeofhexheadboltandmaybedifficultto
sourcelocally.Ifonecannotbeeasilylocated,a5mmx.8
pitchmetricboltmaybesubstituted.Thethreadpitchis
nearlyidenticaltothe#1032size,buttheoutside
diameterisafewthousandthsofaninchlarger.The5mm
boltthreadedintothe#1032holewillbeserviceablein
thissituation.Ifthemetricboltwillnotthreadineasily,
runthe#1032tapthroughtheholeagain.
First,hookthe200toothbeltaroundthepulleyontheX
steppermotor.Assemblethebearingstothepulley
blockwith5/1618x2"socketheadcapscreworhex
headbolt.Asonthegantrypulley,usetwofender
washersasflanges.Useasingleflatwasherbetween
eachfenderwasherandthebearings.Hooktheother
endofthebeltaroundthepulleyassemblyanddropit
downintoposition,asseenintheleftimage.
Asseentotheright,inserta5/1618x2.5"sockethead
capscrewthroughtheholethatisadjacenttothepulley
block.Installawasherandnutontheotherendofthe
screwandtighten.Thiscapscrewservesasasolidstud,
againstwhichthepulleyadjusterwillpush.
Installawasherandnutonthebottomoftheidlerpulley
centerboltandtightensothattheblockisjustfreetoslide
sideways.Withasmallwrench,backthesmallhexboltout,
toputtensiononthebelt.Whenpropertensionhasbeen
achieved,tightenthenut.
Installthebeltplate(part#09)andthebeltclamp(part#10)
asseenintheimagetotheright.AsontheYbeltclamp,
installasmallshimbehindthetopedge,ascircledinred.
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cablearmassembly
Usingtheexplodedviewdrawingonpage35,assemblethe
cablearms,asseentotheleft.Makecarefulnoteofwherethe
largediameterwasherswithenlargedholesareplaced.
Thebearingsinthisassemblyarebeingusedasthrustbearings,
whichisnotthedirectioninwhichtheyareintendedtobe
loaded.Toavoidprematurewearofthebearings,thenutson
thestudsmustbeadjustedsothattheyaretightenoughtohold
theassemblyrigid,butnotsotightastointroduceexcessiveside
loads.Thebearingsarebeingusedinthismannerbecausethey
arethesametypethatareusedthroughoutthemachine,and
areinexpensivewhensourcedinbulk.Theycouldeasilybe
replacedwithproperthrustbearingsifdesired.
Installtheassemblytothegantry,asseenintheupper
rightimage.Thecablearmassemblyshouldcantilever
fromthegantrywithoutsagging.
Pushthegantryallthewaytotherearofitstravel.
Workingfrombeneaththegantry,holdthecablearmsso
thattheyareashorizontalaspossible,andmarkthe
locationsoftheholesinthecablearmmountingblock
whereitcontactstherearplate.
Pullthecablearmassemblyawayfromthemachinebaseand
drilla1/8"pilotholeinthecenteroftheholemarks.Install
themountingblocktothebasewithtwo1/4"x1.25"lag
screws,asseentotheright.
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epoxybed
Tofacilitatealignmentofthemachinetoahighlevelofaccuracy,
aperfectlyflatsurfaceshouldbeusedasareferenceplane,from
whichallmeasurementscanthenbebased.Thereareseveral
possiblemethodsofdoingthis.Thesimplestistousethewooden
bedofthemachineasareferencesurface.Ifitcanbedetermined
thatitisadequatelyflat,itcanbeusedinthiscapacity.Most
likely,itwillhaveenoughdeviationfromtrueflattorequireusing
aflattersurface.Thiscanbedoneinseveralways.Oneisto
temporarilyplaceanobjectknowntobeveryflat,suchasa
surfaceplateorlappedglassplate,securelyonthebedsothatit
cannotmoveduringthealignmentprocess.Asecondmethod,
usedhere,istopourathinlayerofepoxyresinonthebedtolevel
it.Anepoxywithaverylowviscositywillselflevelandresultina
surfacethatisveryflat,creatingarelativelylowcostsurface
platethatisintegratedintothemachine.
Priortopouringtheepoxy,thebedareamustbeaslevel
aspossiblesothattheepoxywillbeaconsistent
thickness.Ifthereisalargedifferenceinthicknessofthe
liquidepoxy,surfacetensioncanresultinanimperfect
finishedsurface.Alargervolumeofepoxywouldbe
requiredtoovercomethistendency.Tolevelthe
machine,placeitonasolidsurfacethatcannotmove
duringthedurationofthetimetheepoxyrequirestocure
(atleast24hours).Themachinecanbeplacedonfour
boltswithnutsthreadedontothem,toserveas
adjustablefeet.Theboltsusedherewere3/8diameter.
Withthemachineonasolidandstablesurface,usea
highqualityleveltosetthebedofthemachineaslevelas
possible.Checkforlevelinmultipledirections,asseenin
theimagesonthispage.Usetheboltstoadjustthe
cornerheightsofthemachineasnecessarytoachievea
levelmachinebedarea.Notethatifthebedareaisnot
perfectlyflat,whichistobeexpectedduetotypicalwood
constructiontolerances,achievingalevelbedmaybea
compromisebetweenerrorsinseveraldirections.Find
thebestaverageoftheerrorsthatispossible.
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epoxybed
Topourtheepoxy,itisnecessarytoestablishawatertightdam
tocontainittothebedarea.Thiswasdoneherewithstripsof
painter'stapeappliedtothefrontandrearedgesofthebed.
Thepouredepoxywillonlybeapproximately1/8thick,but
makesurethedamissignificantlyhigherthanthis.Whatis
mostimportantisthattheareawillhavenoleaks.Theepoxyis
verythinandwillrunoutofthesmallestcrackorareaof
porosity.Makesurethejointbetweenthebedofthemachine
andtheverticalskinpanelsiswatertight.Ifindoubt,
additionalpaintmaybeappliedtosealveryfineopenings,ora
caulkmaybeusedforlargergaps.
Useanepoxywithaslowaviscosityaspossible.Thebrandused
herehasaviscosityofabout550cps,whichisquitethin.Notethat
thewarmertheliquidepoxyresin,thethinneritwillbe.However,
ifitiswarmedtoomuch,itwillcauseittohardentoofast.Anideal
compromiseistogettheepoxytoabout8590degreesFahrenheit.
Thetemperatureoftheroomshouldalsobehigh.Ifitisnot,the
warmedresinwillcoolveryrapidlywhenspreadthin.Theresincan
bewarmedbyplacingtheclosedcontainersinabucketofhot
waterfor1520minutes.Warmtheresinbeforemixingthetwo
componentstogethertoactivate.Useaslowhardenertoallow
maximumtimefortheresintoflowouttoaflatsurface.
Mixingatotalof24fluidouncesofepoxyresinwillresultinan
averagethicknessofjustunder1/8.Thisisabouttheminimum
amounttocoatabasethatisalreadyreasonablyflat.32fluid
ouncesissuggested,asitwillflowoutacrossthesurfacemore
easily.Themoreinaccuratelythewoodbasewasconstructed,the
moreepoxyitwilltaketoarriveataperfectlylevelcoatingof
epoxy.Althoughahighqualityepoxywillhavefewsolventsand
willproduceverylittleodor,makesurethereisadequate
ventilationintheworkarea.Setupanexhaustfanifpossible.
Doublecheckthatthemachinebedisaslevelaspossibleandmix
theepoxy.Useagraduatedcupforaccuracyandfollowthe
manufacturersmixingdirections.
Pourthemixedepoxyintothebedarea,anduseaspreadertotry
andachieveaconsistentthicknessacrossthesurface.Theresin
willselflevel,soitneednotbeperfect,buttheentiresurface
shouldbecoated,includingintothecornersandedges.Becareful
bothwhenmixingtheepoxyaswellasspreadingitthatexcessive
airbubblesarenotintroduced.Trappedairbubbleswillstand
proudoftheflatplaneofepoxywhendried.Afterspreading,allow
theresintohardenforatleast24hours.Donotdisturbthethe
machineduringthistime.
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coverassembly
Thecoverassemblyisattachedtothebasealongitslower
rearflangebyfourscrews.Otherthanthesescrewsto
secureit,thecoverprimarilyrestsonthemachinebase
underitsownselfweight.
Priortoattachingthecover,thinfoamstripswereappliedtothe
edgesthatwillcontactthemachinebase.Thesewerealso
appliedtothesurfaceswherethetwohalvesofthecovercome
together.Thefoamwillcushionthecovertopreventvibrations,
aswellassealanygapstopreventsoundtransmission.The
foamusedherewascutfromsheetsofamediumdensityfoam
rubberthatwaspurchasedatacraftstore.Itwasappliedwith
ahightemperaturehotmeltgluegun.
Twofluorescentstriplightswereinstalledinthetopinsideof
thecover.Slotswereroutedinthebottomoftheflangeto
allowtheirpowercordstoexitthecover.Thefoamstripswere
installedinamannertoallowplacementofthecordsbeneath
them.
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coverandreardoor
Stripsoffoamwerealsoplacedaroundtheperimeterof
thereardoorface,whereitwillcontactthemachine
base.Aholewascutinthedoorwiththeholesawfor
passageoftherouterpowercord.Thedoorwasfastened
withsixwoodscrews.
Areardoorisfitted,tocovertheholeattherearofthe
machine.Theintentofprovidingthedooristhatitcanallow
stockthatislongerthanthemachinebedtopassthrough,
givingalargereffectiveworkarea.Dependingonanticipated
frequencyofuseofthisfeature,thereardoorcaneitherbe
screwedinplace,asseenhere,orcanbeinstalledwithhinges
foreasieroperation.
Alatchwasnotinstalledonthefrontdoor,asitisheldinplace
duringmachineoperationbyitsselfweight.However,alatch
maybeinstalledifdesired.Liftingthefrontdoor,itcansimply
berestedontherearcoverhalf.
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installationofelectronics
INSTALLATIONOFELECTRONICS:
Acompleteguidetoinstallationoftheelectronicdrive
componentsisbeyondthescopeofthismanual.Thisis
largelyduetothevastnumberofdifferentdrive
manufacturersandmodels,eachwiththeirownwiring
requirements.
Abriefinstallationoverviewoftwopopulardriveboardswill
becoveredhere.However,thisshouldbeusedas
REFERENCEONLY,andthemanufacturer'sinstallation
instructionsshouldbeconsideredthedefinitive
documentationforwiring.Thetwodrivescoveredherewill
betheXylotexandtheGeckoG540.Wiringdiagramsare
givenforeach,includingemergencystopswitchesandlimit
switches.Thereareoftenmultiplemethodsofconfiguring
theseswitches,soagainthesediagramsshouldbeusedas
reference,andconsideredsupplementaltothe
documentationprovidedbythemanufacturer.
Whiletheinstallationsshownhereareforspecificmodels
ofdriveboards,thegeneralproceduremaybesimilarfor
modelsofboardsfromothermanufacturers.
Machineoperationispossiblewithaminimumof
components:apowersupply,driveboard,andstepper
motors.However,thesystemshouldnotbeconsidered
completewithouttheadditionofanemergencystopswitch
andlimitswitches.Theseprovideprotectiontoboththe
machineandoperator.
GeneralElectronics
InstallationSequence:
1. Installwiringtomotors
2. Determinelocationsof
componentsinelectronicsbay.
3. Connectpowersupplyto
motordrive.
4. Connectmotorcablesto
motordrive.
5. Connectemergencystop
switch.
6. Connectlimit/home
switches.
7. Firmlyfastenallcomponents
inplace.
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wiringthemachine
Itcanbehelpfultoinstalltheelectronicsonthemachinebefore
makingitsfinalmechanicaladjustments.Thiswillalloweasily
joggingthemachineintomultiplepositionswiththecomputer,
whichwillespeciallybehelpfulontheZaxis.Theexactwiring
procedurewilldependontheparticularmotordrive(s)and
othercomponentsbeingused.Also,ifelectronicscomponents
arepurchasedasakit,muchofthewiringmayalreadybedone,
usingpreinstalledconnectors,resultinginanearlyplugand
playsystem.Thissectionwillillustratethegeneralroutingof
cablesonthemachine.
Thecablearmsprovideameansoforganizingthecablesthat
runtothegantry,andcontrolhowtheyareflexedasthe
machinetravels.RoutethewiringfortheYandZstepper
motorsasshowninthephotos.Simplecabletiesareusedto
securethemtothecablearms.Besurethatthereisnoway
thatthecablescanhookanythingorbindasthegantryand
carriagemovethroughtheirfullrangeofmotions.Besureto
provideenoughcablelengthonall3steppermotorsto
adequatelyreachthelocationofthedriveboard,withoutbeing
pulledtaut.Thepowercablefortherouter,andlimitswitch
wiringcanalsoberunalongthecablearms.Trytomaintainas
muchdistancebetweeneachoftheseparallelcablesas
possibletopreventtransferenceofelectricalsignalnoise.
Theverticalthreadedrodsonthecableplateandthecenterof
thegantrymaybeusedforcableattachment.Itmaybefound
thatthecablingflexesmoresmoothlywithoutfasteningitto
therodonthegantry.Ifthisrodisnotused,cutitdownshorter,
sothatcablescannotgetcaughtonit.
Intheimagetotheleft,thelocationwherethedriveboard
willbemountedhasbeenmarked.Itwillbemountedon
thefournylonstandoffsthatarenexttothescrews.An
awlwasusedtocreateapilothole,andthemounting
screwswerefullythreadedintopositionwithouttheboard
present.Thiswillformthreadsintothewood,whichwill
allowamorecarefulfeelforhowtighttheyarewhen
installingtheboard.Thiscanhelpavoidovertightening,
puttingtoomuchpressureagainsttheboard.Thisalso
preventshavingtoputalotofpressureonthescrewdriver,
whichcouldcauseittoslipoffanddamagetheboard.
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cables
Therearemultipletypesofcablewhichareadvertisedforuse
onCNCmachines,andnotallareequalinperformance.Three
typesareshownintheimagetotheright.Thereareseveral
attributesthatareimportanttoconsiderformachinewiring.
Thefirstistheflexibilityofthecable.Asthemachinemoves
througharangeofmotion,thecablesmustflexto
accommodatethatmovement.Therearedifferentflexibility
ratingsavailable.Allthreecablestotheleftareadvertisedas
flexible,however,onlytheoneonthefarrightisclassifiedas
continuouslyflexibleandisratedformillionsofmovement
cycles.Itslargediameterisduetoathicksiliconerubbercasing.
Itcanalsobeseenthatthiscablehasahighnumberofveryfine
wirestrands,ratherthanafewthick,stiffstrandswhichwill
fatiguequickly.Theothertwocablesareonlyflexibleinthat
theycanbeflexedintopositionduringawiringinstallation.
Theyarenotintendedtobesubjectedtoflexingduringservice.
Ifcontinuouslyflexedtheymaybreak.Thisiscrucial,asmany
typesofdriveswillbedestroyedifawirebreakswhileitisunder
power.
Theothercablefeatureseenhereisshielding.Shielding
providesawaytoneutralizeelectricalnoise,whichmaycause
problemswithmotoroperation,orfalselimitswitchsignals
beingsenttothecontrolsoftware.Wiresmaybetwistedin
pairs,whichalsohelpstoneutralizenoisesignals.Thecableon
thefarleftisunshielded.Themiddleoneusesathinmetalized
mylarstrip.Therightoneusesaheavystainlesssteelbraiding.
Wheninstalledonamachine,thisshieldingtapthatruns
throughthecablewillbeconnectedtoground.
Somemethodshouldbeusedtoprovideasealwherethe
cablesenterthemachinehousing.Withoutthis,dustwillbe
abletoentertheelectronicsbay.Thecablesshouldalsobe
securedinsomemanner,sothattheycannotaccidentallybe
pulledthroughthehole.Theplugsshownhere,inthe
imagestotheright,weremilledfrom3/4MDF,andwerethe
firstpartstobecutonthefinishedmachine.Thecuttingof
thesepartscanbeseenonpage168.Theyfitbyalight
pressfit,andweretappedintoplacewithamallet.They
gripthecablestightly,preventinganymovement.
XB# XB XA# XA YB# YB YA# YA ZB# ZB ZA# ZA
P10
P12
P13
P11
P14
P1
P15
P16
P17
GND
VCC
GND
VBB
GND
MS1
MS2
ENA#
XAXIS
MS1
MS2
ENA#
XAXIS
MS1
MS2
ENA#
XAXIS
G
N
D
E
N
A
Z
E
N
A
Y
E
N
A
X
GND
VBB
TPX
TPZ
TPY
G
N
D
D
I
R
_
A
S
T
E
P
_
A
V
C
C
GND
VCC
2
4

v
o
l
t

p
o
w
e
r

s
u
p
p
l
y
24vcoolingfan
toelectrical
outlet
toXmotor toYmotor toZmotor
1
0
K
1
0
K
1
0
K
X

l
i
m
i
t
X

l
i
m
i
t
Z

l
i
m
i
t
Y

l
i
m
i
t
Y

l
i
m
i
t
1
0
K
emergency
stopswitch
NOTE:
Alllimitswitchesandemergency
stopswitchtobewiredNC
(normallyclosed.)
NOTE:
Colorofmotorwiringmayvary,
dependingonmanufacturer.
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electronicsXylotexwiringdiagram
wiringdiagramfor
XYLOTEX3axisboard
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electronicsinstallationXylotex
INSTALLATIONOFXYLOTEXDRIVE
Wirethepowersupplytothedriveboard.Thisisbestdoneoff
themachineatfirst,astheboardrequiresadjustmentstobe
madetoit.TheXylotexrequiressettingtheindividualoutput
voltageforeachmotoraxis.Thiscanallowuseofmotorswith
differentpowerrequirementsoneachaxis.Thisadjustmentis
donewithonlythepowersupplyhookedup,NOTTHEMOTORS,
andusingadigitalmultimeter(leftphoto).Asmall
potentiometeristurnedtoachievethedesiredoutputvoltage.
ConsulttheXylotexdocumentationforyourboardtodetermine
thevoltagevaluethatisrequired.Besuretonotexceedthe
maximumvoltagespecified,asdamagetotheboardcanoccur.
Withthis"Vref"voltagesetforeachaxis,theboardcanbe
wiredtothemotors(rightimage).
Intheimagetotheright,thedriveboardismountedand
wiredtothepowersupplyandmotors.Thepowercord
forthepowersupplyentersfromtheright,andisrouted
upovertheboardandintototheleftsideofthespace.
Noticeitisknottedtopreventitfrombeingpulledthrough
thehole.
Whenusingthisboardatitshigherrangeofpossible
voltageoutputs,acoolingfanisrequired.Hereasmall
fanismountedtoasmallpieceofpapermatboard,
whichisheldinpositionwithsmallwoodscrews.The
fanispoweredbythedriveboarditself,andispositioned
whereitwillblowairovertheheatsinksontheboard.
Acoupleofsmallpiecesofwoodblockingwereattached
tothetopsurfaceoftheelectronicsbay.Thepower
supplywasattachedtothis,essentially"hanging"from
thetop.Thisputitinaconvenientorientationtorunall
ofthewiring.
Planyourlayoutcarefullysothatwiringisneatandis
easilytraceable.Morewiringwillbeaddedlaterforan
emergencystopbuttonandaxislimitswitches,soplanfor
thiswiringaswell.
YAXIS XAXIS ZAXIS AAXIS
TRIM
PARALLELPORT
A
9
8
7
6
B
1
2
3
4
5
R
STP=DB25P4
STP=DB25P5
TRIM
A
9
8
7
6
B
1
2
3
4
5
R
STP=DB25P2
STP=DB25P3
TRIM
A
9
8
7
6
B
1
2
3
4
5
R
STP=DB25P6
STP=DB25P7
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electronicsGeckoG540diagram
wiringdiagramfor
GeckoG540driveboard
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electronicsGeckoG540installation
INSTALLATIONOFTHEGECKOG540DRIVE
IfoperatingtheGeckoG540drivewithsupplyvoltageandoutput
currentsthatarenearthehighendofitscapacity,heatsinks
shouldbeinstalledtoreduceoperatingtemperatures.The
heatsinksbeinginstalledherewerepurchasedasakitfrom
Soigeneris,andareintendedspecificallyforuseonthisdrive.It
suppliesthreeindividualheatsinks,whichareattachedwith
includeddoublesidedtape.
Thematingsurfacesoftheheatsinksandthebottomofthe
driveshouldbecleanedwithrubbingalcoholbefore
installation.Carefullyapplythetapetothebottomofthe
drive.Asseenintheimagetotheright,holeswerecutinthe
tapeatlocationsofsubtlyprotrudingscrews,toallowthe
heatsinkstositasflushtothesurfaceaspossible.
Carefullypositionandadheretheheatsinksintopositionon
thebottomofthedrive.Inadditiontotheheatsinks,afan
canalsobeusedtofurtherreducedrivetemperatures.
t
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XB
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XA
resistorvalue=
motorcurrent
ratingx1000
TypicalGeckoG540
bipolarmotorwiring.
NOTE:
Colorofmotorwiringmayvary,
dependingonmanufacturer.
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electronicsGeckoG540motorwiring
TheGeckoG540driverequiresinstallationofa1/4watt,
5%resistorinthewiringtoeachmotor,toproperlycontrol
theamountofcurrentthatissuppliedtothataxis.Asper
theGeckodocumentation,thisresistorisinstalledatthe
driveendofthemotorwiring,withintheDB9connector
backshell.Thevalueofthisresistorcanbefoundby
multiplyingthemotorcurrent(upto3.5amps)x1000.
Thus,fora2.5ampmotor,theproperresistorwouldbe
2.5Kohm,5%,1/4watt.
Thereareacoupleofalternativestoinstallingthisresistor.One
istopurchaseaG540kitfromasupplierwhoincorporatesthe
properresistordirectlyintomoldedwiringfortheirmotors.
Thisavoidshandsolderingmotorsupplywiringandsourcing
theproperresistor.Itresultsinasystemthatisvery
convenienttoassemble,beingnearlyplugandplay.
Anotheralternative,ifsolderingyourownmotorcables,isto
useaSoigenerisEZG540.Thiscomponent,whichisshownin
thethreeimagestotheright,incorporatesanadjustable
potentiometerintoaDB9backshell.Byusingthisdevice,it
eliminatessolderingaseparateresistor.Italsoprovideslarge
solderpadsforthemotorwiring,makingsolderingeasierthan
withinastandardDB9connector.Onceinstalled,the
potentiometerisadjustedtosettheproperresistancevalue.
Adigitalmultimetermustbeusedtomeasurethissetting.
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electronicsGeckoG540installation
Withtheproperresistorinstalledinthemotorcables,theycan
beinstalledonthemachine,asperpage143.Intheimageto
therighttheyareseenextendingintotheelectronicsbay.
Alsoseeninthisimageisthatthelocationofthedriveboard
hasbeendetermined,andmountingscrewswithnylon
standoffshavebeeninstalled.
Intheimagetotheright,thepowersupplyhasbeenplacedin
theelectronicsbay.Itisnotyetfastenedinplace,allowing
movementforeaseofmakingwiringconnections.Itsleadsare
routedtothepositionofthedriveboard.
Oneendofthewiringfromanemergencystopswitchhasalso
beenconnectedtothepowersupplyground,andisplacedin
positiontobeconnectedtothedrive.
Thefirstconnectiontothedrivethatshouldbemadeisto
connectonlythepowersupply.Connectthepositiveleadto
terminal11andthenegativeleadtoterminal12.Withthe
powersupplyconnected,turniton,andtheredLEDonthe
boardshouldilluminate,asseenintheimagetothelowerleft.
AfterverifyingthattheredLEDilluminates,turnoffthepower
supply.Connecttheleadfromtheemergencystopswitchto
terminal10.Thisswitchshouldbewirednormallyclosed.As
pertheGeckoinstructions,disablethechargepumpswitch.
Turnonthepowersupply,andthegreenLEDonthedrive
shouldilluminate.
TurnoffthepoweragainandattachthemotorcableDB9
connectorstothedrive.Thesystemshouldnowbe
operational.ConnectaDB25cabletothePCparallelport,and
checkthatthemachinecanbejoggedthrougheachaxisby
usingthemachinecontrolsoftware.
Thefinalinstallationstepistoadjustthetrimpotofeachaxis
onthedrive.ConsulttheGeckodocumentationforthis
procedure.Itismosteasilyaccomplishedwiththemotors
disconnectedfromthebelts/leadscrew.Tokeepthemotors
turningatthedesiredrpmfortuning,ashortGcodeprogram
canbewritten,orthejoggingspeedadjusted.
Xlimit Ylimit Zlimit
Xhome
Yhome
Zhome
P10
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P12
P13
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electronicslimitswitches
Regardlessoftypeofmotordriveused,thesystemshouldbeinstalledwithlimit
switches.Thesearesmallmicroswitchesinstalledjustbeforetheendoftravelon
eachaxis.Whenthemachinereachesthispointintravel,theswitchis
triggered,sendingasignaltothemachinecontrolsoftware,whichstopsmotion.
Thispreventsthemachinefromaccidentallyslammingintotheendofitstravel,
potentiallycausingdamageoroperatorinjury.
Inadditiontoaddingalevelofsafety,theycanalsobeusedtohomethe
machine.Eachtimethemachineisturnedon,themachinecontrolsoftware
canbeinstructedtohomeallaxes.Thesoftwarewillsequentiallymoveeach
axisofthemachineinadesiredhomingdirection,untilittriggersaswitch.Itwill
thenbackofftheswitchasmallamountsothatitisnolongertriggered.The
softwarewillconsiderthisthezerocoordinatehomepositionfortheaxis.This
willprovideaconsistent0,0,0startingpositioneachtimethemachineisused.
Thesoftwarewillnowknowwherethetoolispositionedinspace.
Notethatthis0,0,0machinecoordinatedoesnothavetobeconsideredasthe
0,0,0positiononapartwhenrunningajob.Aseparate0,0,0workoriginpoint
canbesetforeachjob.Thisexistsindependentlyofthemachinecoordinates,
whichwillalwayshave0,0,0inthesameposition.
Havingconsistent0,0,0machinecoordinatesthatarefoundthroughhoming
allowsuseofsoftlimits.Thesearetravellimitsthataresetthroughthe
software,thatpreventthemachinefromtravelingasfarasalimitswitchduring
operation.ThiswillbediscussedmorefullyinthesectiononMach3setup.
Limitswitchescanbeinstalledinmanywiringconfigurations.Generally
speaking,acompromisemustbefoundbetweengivingthesoftwareasmuch
knowledgeofmachinepositionaspossible,whilenotusinganexcessivenumber
ofparallelportinputpins.Thediagramsonthispageillustratesomeofthe
potentialconfigurationsforwiringthesamenumberofswitches.
Atoneextreme,allswitchescanbewiredthroughasinglepin.Nomatterwhich
switchisactivated,motionwillbestopped.However,thesoftwarewillhaveno
wayofdeterminingwhichswitchwastriggered.Correctmachinehomingcan
stillbedone,asthesoftwareknowswhichaxisitisputtingintomotion.
Attheotherextreme,eachswitchiswiredtoaseparatepin.Thisgivesthe
softwarethemaximumknowledgeofwhichswitchistriggered.However,it
requiresmoreinputpinsthanaretypicallyavailable,inadditiontoalarge
amountofwiring.
Thediagraminthelowerrightwasusedonthismachine.Itisconsideredagood
compromisebetweenmaximizingsoftwareknowledgewhileminimizinginput
pins.Notethatlimitswitchesarealwaysinstallednormallyclosed,sothatany
breakageofwiringwillstopthemachine.AlsonotethataswitchintheZ
directionisnotused.Duetothevariabilityoftoollengths,itismorepracticalto
controlmotioninthisdirectionthroughsoftlimits.
NOTE:
Diagramsrepresentinputlogiconly,
theyarenotwiringdiagramsforany
specificdrive.Particulardrivesmay
requireresistorsateachswitchinput.
Consultdocumentationfromdrive
manufacturerforrequirements.
pin11
pin12
GND
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electronicslimitswitches
Asingle,4conductorcablecanbeusedtowirethelimit
switchesfortheZandYaxes.Ageneraldiagramofthis
configurationisshowntotheleft.Notethatsomedrives,
suchastheXylotex,mayrequireresistorsateachswitch
inputpin.
Theimagetotherightshowsthiswiringasitwasappliedto
aGeckoG540drive.Notethatthiscableisshielded,andthe
tapisalsoconnectedtothegroundpoint.Thecoilofsingle
wireinthecenterwillbeusedfortheXaxislimitswitches.
Intheimagetotheright,allofthelimitswitchwiringis
connectedtotheGeckodrive,aswellasgroundedtothe
powersupply.Withalloftheconnectionsmade,thedriveis
securedinpositiononthenylonstandoffs.
Wiringwassolderedtothemicroswitchconnectorsbefore
attachingthemtotheirmountingbrackets,asseentotheleft.Be
suretoconnectthewiringtothecorrectlugs,sothattheswitch
willbeoperatinginthenormallyclosedconfiguration.
Theswitchesarenextinstalledonthemachine.Theimagetothe
rightshowsthefrontXaxisswitch,whichistriggeredbythe
extendedlengthofthreadedrod.Asmallholeisdrilledtoroute
thewiringdirectlyintotheelectronicsbay.
toground
topin11
topin12
toYandZaxis
limitswitches
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electronicslimitswitches
TheXaxislimitswitchesaremountedasseenintheimagestothe
leftandright.Thebracketswereattachedtothebasewithscrews.
Astackofwashersisusedasaspacerbetweenthebracketand
base,withtheswitchsittingtightlytothesurfaceofthebaseskin.
Installtheswitchesinapositionwheretheyaretriggeredbythe
extendedlengthofthreadedrod.Installthemountingscrewsso
thatthereissomeamountofadjustabilitytothebrackets.The
switchesshouldbeabletobeadjustedsothattheytriggerabout
1/4awayfromanyhardcollisionattheendoftheaxistravel.
ThesingleZaxisswitchismountedasintheimagetothe
right.Itisalsotriggeredbyanextendedlengthofthreaded
rod.Washerswereusedbehindthebracket,toprovide
clearancefortheheadsofthescrewsthatattachtheswitchto
thebracket.
MountingtheYswitchesonthegantryrequiresdrillingand
tapping#1032holesinthegantrytube,asseenintheimage
totheleft.Carefullydeterminetheplacementoftheswitches
beforedrilling.NotethattheYswitchesaretriggeredbythe
outermostcarriagebearings.
TheimagestotheleftandrightillustratetheinstalledYaxis
switches.Washerswereagainusedbetweenbracketand
gantrytoprovideclearanceforscrewheads.Wiringwas
fastenedtothegantrywithstripsofelectricaltape.
Withallswitches,makesurethattheconnectorscannot
possiblygroundtoanypartofthemachine,asthiswill
interferewiththeirproperoperation.
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sidedoor
Asidedoormaybeprovidedtocovertheelectronicsbay.This
isalsoaconvenientsurfaceformountinganemergencystop
switch.Adoorcanbefabricatedfromanyflatmaterial.Dueto
this,thematerialforthedoorhasnotbeenincludedintheBill
ofMaterials.Thedoorshownherewascutfromapieceof
polycarbonatesheet,whichwassandedonbothsideswithfine
sandpapertogiveitafrostedappearance.
Theonlylimitationondoormaterialisthatitshouldbeableto
withstandtheforceofhittingtheemergencystopswitchifitis
mountedhere.
Theholefortheemergencystopswitchwascutbystitchdrilling
andfiling.Thesametechniquewasusedtocutaholefor
mountingtheinputcablefortheelectronics.Aseriesofholes
werealsodrilledtoprovideairflowforthepowersupplyfan,anda
coolingfanthatwillblowairacrossthedriveboard.
Thedoorwasmountedwithtwo11/2utilityhingesandtwo
magneticlatches.Alengthofwoodwasscrewedtothedoorto
provideahandle,andtostiffentheedgeofthethinmaterial.
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Mach3setup
Basicsoftwareconfigurationwillallowuseofthecomputerto
jogthemachineduringalignment,andprovidepreparationfor
thefirstuseofthemachine.SetupofMach3softwareisshown
here,althoughmanybasicconceptswillapplytoother
applications,suchasEMC2.Extensivedocumentationis
providedbythesoftwaredevelopers,anditshouldbefollowed
closely.Thesetupshownhereshouldbeconsideredas
supplementalreference,andisnowayintendedtoprovidethe
fullknowledgenecessarytousethesoftware.
Ifyouhaven'talready,installthesoftwareperthedeveloper's
directions.Thismayinvolverebootingthecomputerand
runningaprogramtotesttheoperationoftheparallelport.
SomemanufacturersofmotordriveswillalsoprovideaMach3
.xmlfile,whichcreatesaprofilethathasnumeroussettings
preconfiguredfortheparticulardrive.Geckoisonesuch
manufacturer,whichprovidesa.xmlfileforitsG540drive.Ifan
.xmlfileisavailableforyourdrive,installitintheMach3install
folder.
ParallelPortsettings:
Config>PortsandPins>PortSetupandAxisSelection(upper
rightimage)
Thisscreenisusedtoactivatethecorrectport.Consultingthe
WindowsDeviceManagermaybenecessarytodeterminethe
portaddress.TheothersettingonthisscreenisforKernel
Speed.Thissettingdeterminesthefrequencyoftheoutput
pulserate.Ahigherpulseratetranslatestohighermotorrpm.
Fortypicalsteppermotorsystems,25,000Hzisadequate.
Config>PortsandPins>MotorOutputs(middlerightimage)
Themotorwiringmustbeconfiguredtocorrespondtospecific
parallelportpinstoreceiveproperoutputsignals.Consult
motordrivedocumentationforthisinformation.Ifusingadrive
specific.xmlfilethisshouldalreadybeset.
Jogging:
OnmostscreenswithinMach3,thearrowkeysandPgUp/PgDn
canbeusedtojogthe3axes.Thisfunctionmayneedtobe
configuredbygoingtoConfig>SystemHotkeys.Inadditionto
usingkeyboardinput,theManualPulseGeneratorflyoutmay
beused.Pressingthetabkeymakesthisscreenappear,and
givesincreasedfunctionalityforjogging.Thiscanbeusedfor
continuousjogging,orbydiscretesteps.Donotusethejogging
functionuntilthecorrectmotorsettingshavebeenentered
(followingpage.)
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Mach3setup
MotorTuning:
Config>MotorTuning>desiredaxis
Thesoftwaremustknowhowmanysteppulsesmustbesentto
themotorstoresultinmachinemovementofoneunit(inchor
mm.)
FortheXandYaxisbeltdrives:
Motorstepsperrevolution=200
Timingbeltpitch(.200)xteethonpulley(10)=2.00perrev.
Microsteppingvalue(GeckoG540=10x)
Onemotorrevolution(200steps)=2.00ofmovement.Thus
100motorsteps=1inchoftravel.However,sincethemotor
drivehasamicrosteppingfeature,thisresultsinahighernumber
ofstepsperrevolution.Thus,fora10xmicrosteppingdrive,10x
microsteppingX100steps/inch=1000steps/inch.Forthis
drive,1000steps/inchwillbethevalueenteredintheXandY
axisfieldstitledStepsper.
FortheZmotoraxis,thefactorsare:
Motorstepsperrevolution=200
Leadscrewpitch(1/8x4startacme)=.50perrevolution.
Microsteppingvalue(GeckoG540=10x)
Onemotorrevolution(200steps)=.50ofmovement.Thusit
requires2revolutionsofthemotorshafttocauseoneinchof
movement,or200stepsX4revolutions=400steps/inch.
Factoringthemicrosteppingfeature,thisagainresultsinahigher
numberofstepsperrevolution.Thus,fora10xmicrostepping
drive,10xmicrosteppingX400steps/inch=4000steps/inch.
Forthisdriveandparticularleadscrewpitch,4000steps/inchwill
bethevalueenteredintheZaxisfieldtitledStepsper.
Velocity:
Thissetsthemaximumspeed,whichisusedduringjoggingor
rapidmoves.Thismaybelimitedbytheparticularelectronics
beingused,butingeneralthemachineiscapableofveryhigh
speeds.Thisshouldbekepttoareasonablespeedtoavoidthe
machinemovingfasterthantheoperator'sresponsetimetohit
theemergencystopswitch.
Acceleration:
Thissetstheaccelerationanddecelerationofthemotors.This
shouldalsobekepttoareasonablevalue,assteppermotorscan
becomegeneratorsunderdeceleration.Thiscanfeedexcessive
voltagebacktothedrive,potentiallycausingdamage.
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Mach3setup
LimitSwitchInputs:
Config>PortsandPins>InputSignals
Thesoftwaremustbeconfiguredtoknowwhenalimitswitchis
beingactivated,aswellasknowingonwhichaxistheeventis
occurring.Theimagetotherightshowstypicalsettingsthat
correspondtothewiringdiagramusedonpages151/152.The
port#mustcorrespondtowhichparallelportisbeingusedto
controlthedrive.Thepinnumbercorrespondstohowthelimit
switchesarewiredthroughthedrive(orbreakoutboard.)Onthe
GeckoG540andXylotexdrives,certainterminalconnections
correspondtocertainparallelportpinnumbers.
HomeReferencing:
Config>Homing/Limits
Themachinecanbeinstructedtosequentiallymoveeach
axisinadetermineddirection,untilithitsahome
switch.Thelimitswitches,configuredabove,canalsobe
usedforthishomingoperation.Noseparateswitchesare
required.Bycheckingautozero,asseenintheimageto
theright,anaxiswillbeincludedinthehomingoperation.
TheXandYaxesaretypicallyhomedinthenegative
direction,whiletheZishomedpositive.Duetothe
particularmotorwiring,hereitcanbeseenthatthe
directionoftwomotorsrequiredreversing,inorderto
orientthecorrectpositive/negativemovementdirections.
ActivatingtheREFALLHOMEcommand(circledinredin
thelowerrightillustration),eachaxiswillmoveata
reducedspeeduntilitcontactsahomeswitch.Itwill
thenbackawayfromthehomeswitchslightly.This
positionwillbethezerocoordinatefortheaxis.These
three0,0,0locationssetthemachinecoordinates.
Softlimits:
Config>Homing/Limits
Ratherthandependonlimitswitchesforendofaxis
protection,travellimitscanbesetthroughthesoftware.
Thesearedistancesfromthe0,0,0machinecoordinates.
Theadvantageofusingsoftlimitsisthatthemachinewill
gentlydecelerateasitapproachesthistravellimit,unlike
theabruptstopcausedbyhittingalimitswitch.
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alignment
Atthispointthemachineisbasicallyfinishedandprimarily
needsalignmentbeforeuse.Thefirstalignmentstepwillbeto
getthetwoXrailsexactlyparalleltothesurfaceofthemachine
bed.Thisisdonebymeasuringupfromthebedatthefront
andrearofeachrail,andadjustingthemsothatthe
measurementsareequal.Thiscanbeaccomplishedtoahigh
levelofaccuracywithsomerelativelysimpletools.
Theimagetotheleftillustratesanadjustableheightgaugethat
wasconstructedfromsomescraprectangulartubinganda
lengthofthreadedrod.Thetubingsizewas11/2"x2".The
surfacesofthetubingareveryflatandallowthegaugetosit
flushagainstthebedwithoutrocking.Thetopofthethreaded
rodwasfiledtoashallowpoint.Noteintheimagestothe
rightthatthethreadedrodwasbentveryslightlytothesideso
thatitwouldreachexactlyundertherails.
Theheightgaugeisusedinconjunctionwithasetoffeeler
gauges(middleleftimage.)Thesearesimplythinflexiblemetal
stripsthatareinsertedintoagapto"feel"howwideitis.They
canbepurchasedatanyautopartsstoreforafewdollars.
AdjustthethreadedrodupunderthefrontoftherightXrail
untilitisalmosttouching.Ideally,leaveabout.010"of
clearance.Usethefeelergaugestomeasurethisgap.Withtrial
anderror,findthefeelergaugestrip,orcombinationofstrips
together,thatslidesintothegapwithjustafaintamountof
dragalongitssurface.Withoutchangingitsadjustment,
repositiontheheightgaugeundertherearoftherightrail.
Measurethegapbetweenitandtherailwiththefeelergauges.
Loosentheboltsholdingtherailtotherailangleand
repositionitsothatthegapisthesameatthefrontandrear.
Thismaytakemovingtheheightgaugefromfronttoback
severaltimesandtakingrepeatedmeasurements.Withsome
patience,therailscanbeveryaccuratelypositionedthisway.
Dothesamefortheleftrail.Therightandleftrailshouldeach
bethesameexactsameheightabovethebed.
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alignment
ThetwoXrailsshouldnowbothbeparalleltothemachinebed.
ThenextadjustmentistosettheYrailparalleltothebed.This
isdoneinasimilarfashion,butwewillnowbeadjusting
bearingstoeffectitsheight.
Wewillagainbeusingtheheightgaugeandfeelergauges,this
timetomeasuretheleftandrightsidesoftheYrail(leftand
rightimages.)
ThefourbearingsthatridealongthetopsoftheXrailswill
needtobeadjusted(circledinthemiddlerightimage).Allfour
willneedtobeexertingequalpressuredownwardontherails
sothatthegantrywillnotrock.Again,thiswillrequiresome
trialanderrorandmultiplerepositioningofthemeasuring
gaugeduringtheprocess.Tightenthenutsonthebearing
boltssothattheyarejustslightlysnugandthenadjusttheset
screwtorepositionitbeforefullytighteningthenut(lower
rightimage).
WhileadjustingthesefourbearingstogettheYrailparallelto
thebed,occasionallycheckthatthefrontfaceoftheYrailisas
closetoperpendiculartothebedaspossible(leftphoto).The
closertoperpendicular,theeasieritwillbetoadjusttheZ
axislater.
Takeyourtimewiththeseadjustmentsandbepatient.Itmay
takemultipleattemptstogettheadjustmentcorrectandmay
befrustratingandtimeconsumingatfirst.Theprocesswill
proceedfasterasyoudevelopafeelforadjustingthe
bearings.
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alignment
Onceyouaresatisfiedwiththeadjustmentofthefour
bearingsthatridealongthetopsoftherails,nextadjustthe
fourthatridealongtheloweredge.Movethegantryso
thatthebearingslineupwiththefourdepressionsinthe
innerskins,asshowninthelowerrightimage.Theseare
providedtoallowclearancetogetawrenchontotheheads
ofthebolts.However,astheboltheadsarethinnerthan
normal,itwilltakeaspecialwrenchtofitontothem.
Thereareacoupleofsolutionstothis.Oneistosimplygrind
downtheheadofastandardwrenchsothatitfits.Ifyoudothis,
grindthewrenchslowlytoavoidoverheatingthemetal.Coolit
oftenbydippingitintowater.Anothersolutionistouseaready
madewrench.Manypowertoolshavespecialwrenchestofit
theirarborsthatarethin.Thelowerleftimagesshowsawrench
forarouterthatwastherequired1/2"size.Anotheroptionisto
buyabicycleconewrenchthatismadeforworkingonbicycle
hubs(wrenchwithbluehandleinimage.)Buyoneina13mm
size.Notethatthisisaslightlyloosefitonthe1/2"head(which
is12.7mm)butshouldworkfine.Thesedonotneedtobe
excessivelytightened,sonoroundingshouldoccurifthewrench
issquarelyonthebolthead.
Adjustthesefourbearingsuntiltheylightlytouchthebottom
edgeoftherails.Thisalsorequiresacquiringafeelforhowtight
againsttherailtheyneedtobe.Theyneedtobetightenough
thatthereisnofreeplay,butnotsotightthattheyincrease
rollingresistance.Agoodtestisthatwiththegantrystationary,
youshouldstillbeabletograspthebearingandturnitagainst
therail.Itshouldslipagainsttherailwhenturnedwithsome
pressure.Itshouldnotslipveryeasily,butshouldnotturn
completelyfreelyeither.Thetendencywhileadjustingmaybe
toovertightenthebearings.Itiseasytoovertightenthe
bearingstothepointwherethesteppermotorscannotmovethe
machine,orlosestepsduringmovement.Ifindoubt,itisbetter
togowithanadjustmentthatseemsslightlytoolooserather
thantootight.
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alignment
Mostofthebearingsonthemachineareadjustedin
sets,thatsimultaneouslytouchopposingsidesofarail.
Thismayeitherbeacrossthewidth(leftillustration),or
acrossthethickness(rightillustration).Keepingthisin
mindcanhelpduringadjustments,asthereareacouple
ofstrategiesthatcanbeusedtocauseanadjustmentto
havetheneededeffect.
Adjustingtwobearingsalongonesurface(thetoptwo
bearingsintheupperleftillustration)cancauseeither
rotationalshiftoraparallelshift.Makethese
adjustmentswiththeopposingbearingsloose.
Oncebearingsalongonesurfacearesatisfactory,adjust
intheopposingset(middleleftillustration.)
Ifallfourbearingsaremakingthedesiredamountof
contact,arotationalshiftcanbeaccomplishedby
leavingtwoopposingonesalone,whileadjustingthe
othertwoequalamountsinthesamedirection.(lower
leftillustration.)
Thenextbearingstoadjustwillbethecarriagebearings
thatridealongtheYrail.Firstadjustthefourthatcontact
thetopandbottomedges(circledinthemiddleright
image.)
Whileadjustingthesefourbearings,alsotrytogetthe
carriageitselfperpendiculartothebed,asshowninthe
photototheright.Theclosertoperpendicularthe
carriagecanbeset,theeasierthealignmentoftheZaxis
railandZscrewwillbelater.
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alignment
TheYaxisbearingsthatridealongthefrontandrearfacesof
therailareadjustednext.Thereareatotalofeightbearings,
thatneedtobeadjustedasonegroup.Notethatonthefront
ones,asinglesocketheadcapscrewsecurestwobearingsata
time.Eachbearingdoeshaveanindividualsetscrewadjuster.
Youmayfinditeasiesttoadjustthesedoublesetsofbearings
first(middlerightimage),andthenadjusttherearonesinto
touchtherail(upperrightimage.)
Therearbearingsalsouseboltswiththinnerheadsfor
clearance,sothethinwrenchwillbeneededheretoo.
Likewiththepreviousadjustment,checkoftenduringthis
adjustmenttotryandsetthecarriageperpendiculartothebedin
thefront/reardirection.Again,thiswillmakelaterZaxis
adjustmentsmucheasier,andwillresultinsmootherZaxis
operation.
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alignment
ThenextadjustmentwillbetotheZaxisrail.Thisneedstobe
adjustedsothatitisperpendiculartothemachinebedinboth
sidetoside,andfront/reardirections.
Firstadjustitsidetoside,usingthefourbearingscircledtothe
right.
JogtheZaxisdownsothatitisatthelowestpointofitstravel.
Becarefulthattheraildoesnotmovelowenoughthatititno
longercapturedbetweenthetopbearings.Asmalltriangleor
squarecannowbeusedasagaugetosettherail
perpendicular.
WhentheZrailisperpendiculartothebed,doublecheckby
flippingthetrianglearoundandholdingituptotheother
side.Ifyourtriangleisnotexactlya90degreeangle,orthe
bedsurfaceisuneven,thenflippingthetriangletotheother
sidewillrevealthediscrepancy,andthatsomethingis
inaccurate.
Movethetriangleorsquaretothefrontoftherailasshownin
theimagetotheright.Adjusttheeightbearingsthatridealong
thefront/rearsurfacesoftherailtogetitperpendiculartothe
bed.Thesealsohavepairedbearingsonlongsocketheadcap
screws,sousethetechniquethatwasusedontheYrail.
Allthreeofthemachineaxesshouldnowbeinproper
adjustmentandalignment.
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alignmentZscrew
ThefinaladjustmentistotheZaxisdrivescrew.Thereisno
simpleplacetodirectlymeasuretofinditsproperpositioning,so
itwilltakesometrialanderror.BeginbyjoggingtheZaxistoits
lowestposition.Tightenthe#440x1"machinescrewsandnuts
holdingtheantibacklashnutsothattheyaresnugenoughto
holditinposition,butitcanstillberepositionedwithsomeslight
force.Alsosnuglytightenthenutssecuringthenutplate,andnut
plateblock.Eachofthesepointscanlaterprovideadjustability.
Standinginfrontofthemachine,visuallyalignthedrivescrewso
thatitisparalleltotheZaxisrail.
Movetothesideofthemachineanddothesameinthat
direction.
JogthemachineallthewaytothetopofitsZaxistravel.It
shouldnotbind,andthesoundfromthesteppermotors
shouldstayconsistentduringthetravel.Readjustas
necessary.ItwillprobablyrequirejoggingtheZaxisupand
downseveraltimes,readjustingeachtime,tofinallygetit
correct.
Onceitisinasatisfactoryposition,tightenallofthenuts
fully.Ontheantibacklashnut,besuretoeitheruse
threadlockingcompound(theremovabletype),locknuts,
orlockwashers.Thesearehighlyvulnerabletovibrating
loose,andtheirsmallsizedoesnotallowexcessive
tighteningwithoutstrippingthreads.
Ifallisadjustedcorrectly,theZleadscrewshouldbeparallel
totheZrailwhenviewedbothfromthefrontandfromthe
side.TheyshouldremainparallelinbothdirectionsastheZ
axisisjoggedalongitslength.Bindingmayoccurifthetwo
arenotparallelduringtheentirelengthoftravel.
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routerandmounts
Installtheroutermounts,asseenintheimagetotheleft.
Notethatthemountsshowninthisseriesofimagesare
anoldervariation,andarenotexactlythesameshapeas
thecurrentdesign.
WiththeZaxisjoggedtoitslowestposition,seta
triangleorsquareagainstthefacesthatwillcontactthe
routerbody.Noteifthesquaretouchesbothevenly.If
themountsarenotexactlyperpendiculartothemachine
bedtheycanbeshimmedintothecorrectposition.Thin
metalfoilorpapercanbeusedasshimstock.
Whensatisfiedthatalloftheclampingsurfacesare
perpendiculartothebed,installtherouterandfrontclamp
halves.Tightentosecuretherouter.
Makesurethattherouterandcordclearallmechanical
componentsastheZaxismovesthroughitsfullrangeof
motion.TheextendedthreadedrodthatcontactstheZaxislimit
switchcanalsobeusedtomanagetheroutercord.Besurethat
itcannotinterferewithproperoperationofthelimitswitch.
Hereawasherandnutwereusedtocontainthecord.
5.500
0.5
0.5
1
1.5
2.75
.25
.25
.50
.75
2.750
1.000
1.500
0.500
1.375
.25
.50
.75
1.500
1.000
.75
.50
Typicalextruded
aluminumTslottrack. (2)pieces,MDF.
(4)pieces,MDF.
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spoilboard
Somemethodisrequiredtosecureworkpiecestothe
bedarea.Thebedareashouldalsobeprovidedwitha
sacrificialspoilboardwearsurfacethatcan
accommodatemillingoperationsthatcutthroughthe
entirethicknessofthework.Thespoilboardmaybeas
simpleasapieceofmediumdensityfiberboard(MDF)
thatisfastenedtothemachinebed.Workpiecescanin
turnbescrewedtothissurface.
Amoreversatilesystemisshownhere,whichconsists
ofaluminumTtrackextrusionsthataresetwithinpieces
ofMDF.Thisprovidesaconvenientandfastmethodof
clampingthatdoesnotrequiresinkingscrewsintothe
spoilboardsurface.Manytypesofclampingaccessories
arecommerciallyavailableforTtracksystems.
Theassembledpiecesintheillustrationtotheleftresult
inaworkingsurfacethatmeasures15x15.Thissize
willallowthecuttingtooltojustextendbeyondeach
edge.Thisisnecessarysothattheroutercanbeusedto
millthissurfaceflatafterinstallation.Thespoilboard
canalsoberesurfacedafteritwearsduringuse.
Theassemblyshownhereusedapieceof3/4plywood
asthecenterlayer.ThiswasusedratherthanMDFasit
iseasiertoscrewinto.Anyscrewthatpenetratesinto
MDFshouldbeprovidedwithapilotholetoavoid
damage,astheMDFdoesnoteasilydisplacematerial.
ThetopMDFstripswerefastenedfromthebottom,
throughcountersunkclearanceholesintheplywood
layer.
Thicknessofspoilboard:
TheZaxisofthemachinehasasubstantialamountof
travel,anditshouldbekeptinmindthatthemachine
willbemostrigidwiththeZaxisatitshighest.Thus,it
isbeneficialtomounttheworkpieceashighas
possible.Ifyouanticipatecuttingaconsistenttypeof
parts,suchasmostlypartscutfrom3/4thickwood,
thenthespoilboardcanbeconstructedwiththisin
mind.Itcanbebuilttoathicknessthatraisesthework
toadesiredheight.Thespoilboardcouldalsobe
constructedinmultiplelayers,thatcouldberemovedto
loweritwhennecessary.
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spoilboard
Themiddlerightimageillustratesthefinishedspoilboard
beforemountingonthemachine.Notethatthetopof
theMDFsurfaceiswellabovethetopsurfaceofthe
aluminumTtrack.Thisprovidesasafethicknessofwear
surfacethatwouldneedtobepenetratedbeforethe
cutterwouldcontactthemetaltrack.
Thelowerleftimageshowsonetypeofclampthatis
availableforthisTtracksystem.SpecialTtrackboltsare
alsoavailable,allowingmorecustomclamping
configurations.Itisrecommendedtouseclamp
componentsthataremadeofplastic,brass,orothersoft
metalswherepossible.Thiswillreducethedangerthat
ispossibleifaclampisaccidentallyhitbyacuttingtool.
Intheimagetotheright,thefinishedspoilboardis
mountedonthemachinebed.Itwascarefullylocatedso
thatthecuttingtoolcancutmovejustbeyondits
perimeterforsurfacing.Itwasalsocarefullypositioned
sothattheTslotsareasparalleltotheXaxistravelas
possible.Thismakesiteasiertoclampmaterialtothe
spoilboardinapositionthatisknowntobeparallelto
thataxis.
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firstuse
Congratulations,themachineisnowcompleteandreadytobe
used.AfterfamiliarizingyourselfwithaCAMapplication,and
generatingGcodetocutapart,hereisasuggestedprocedureforthe
firstuseofthemachine.
1. HomethemachinebyusingtheMach3REFALLHOME
command.ThiswillzerotheMachineCoordinates.
2. Jogthemachinesothatthetipofthetoolisinthelocationon
theworkpiecethatcorrespondsto0,0,0asitwasdefinedinthe
CAMsoftware.Wheninthatposition,usethebuttonscircledin
theimagetothelefttosettheWorkCoordinates.Notethatthis
doesnotaltertheMachineCoordinates,whicharestillusedto
controlsoftlimitlocations.
3. Jogthemachinetomakesurethatsoftlimitsarefunctioning
correctly.TheSoftLimitsbutton(alsocircledintheleftimage)in
Mach3needstobeactivated,whichwillbeindicatedbyagreen
borderaroundthebutton.
4. LoadaGcodeprogram.File>LoadGcode.Thelinesofcode
willappearinthewindowthatiscircledintherightimage.
5. Runtheprogram.Forthefirsttimerunningaprogramitis
advisabletozerotheWorkCoordinatefortheZaxishigherthanthe
workpiece.Thiswayyouwillbecuttingairandhavean
opportunitytoobserveiftheprogramseemstoberunning
correctly.Keepahandontheemergencystopbuttonandclickthe
CycleStartbuttoninMach3(alsocircledintherightimage.)Watch
toseethattheaxesappeartobetravelingthecorrectdistance.If
thereareanyproblems,themachinecanbestoppedbyhittingthe
emergencystopbutton,ortheredStopbuttoninMach3(circledat
right.)
6. Ifallappearstobeworkingcorrectly,setthecorrectZaxisWork
Coordinate,jogthetoolasafedistanceabovetheworkpiece,turn
ontherouterspindle,andruntheprogram.Congratulationsagain,
you'vejustcutyourfirstpart.
7. Itisadvisabletomeasurethefinishedpart,tocompareitscut
dimensionstoitsdesigndimensions.Ifthereisanyvariation,the
stepsperinchvaluesintheMach3motortuningscreensmayneed
slightadjustment.
Thisconcludesthebuildingofthemachine,andhopefullybegins
manyenjoyablehoursofmachiningparts.Becreative!
BobPavlik
momus.design@gmail.com
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partssuppliers
SUPPLIERS
Metals
OnlineMetals
1138WestEwing
Seattle,WA98119
800_704_2157
http://www.onlinemetals.com/
sales@onlinemetals.com
SpeedyMetals
locationsinWisconsin,Michigan,Texas
http://www.speedymetals.com/
MetalsDepot
4200ReviloRoad
Winchester,KY40391
http://www.metalsdepot.com/
Bearings
VXBBearings
http://www.vxb.com/
Ebayvendor
userid:irvineman
storename:VXBBearingsSkateboardandSlotcar
StepperMotorDrives
Xylotex,Inc.
2626LaveryCourt#307
NewburyPark,CA91320
http://www.xylotex.com/
support@xylotex.com
http://groups.yahoo.com/group/Xylotex/
GeckoDriveMotorControls
14662FranklinAve.
SuiteE
Tustin,CA92780
http://www.geckodrive.com/
http://groups.yahoo.com/
KelingCNC/AutomationTechnology
AutomationTechnologyInc
2112StoningtonAve
HoffmanEstates,IL60169
http://www.kelinginc.com/
vwideselectionofmotorsanddrives
CNCrouterparts
http://www.cncrouterparts.com/
GeckoG540/motorkitwithmoldedcables
LongsMotor
Ebayvendor
userid:longsmotor99
storename:ChangzhouLongsMotorCo
motorsanddrives.ShipsfromChina.
Soigeneris
http://www.soigeneris.com/
GeckoG540drives
G540heatsinkkit
EZG540DB9connectorswithpotentiometer
PowerTransmission
DumpsterCNC
http://dumpstercnc.com/
dumpster95@yahoo.com
antibacklashnuts
motorcouplings
McMasterCarr
http://www.mcmaster.com/
precisionacmethreadedrod
manymisc.components
StockDriveProducts
http://www.sdpsi.com/
drivebelt
timingpulleys
Epoxy
JamestownDistributors
17PeckhamDrive
Bristol,RI02809
http://www.jamestowndistributors.com/
MASlowviscosityepoxy
Ebayvendor:
userid:polymerproducts
storename:PolymerProducts
lowviscosityresin
Hardware
BoltDepot
www.boltdepot.com
hardware
BOLTITUP
Ebayvendor
userid:5137jones
storename:BOLTITUP
hardware
MultipleItems
HubbardCNC
Ebayvendor
userid:carolbrent
storename:HUBBARDCNCINC
wideselectionofCNCparts
NOTE:
MomusDesignhasnoaffiliationwith
anyofthevendorsonthisorthe
followingpage.Inclusionheredoes
notnecessarilyimplyanendorsement.
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softwaresuppliers
SOFTWARE
MachineControlSoftware
Mach3CNCcontroller
ArtSoft
NewfangledSolutionsLLC
http://www.machsupport.com/
LinuxCNC(EMC2)
http://www.linuxcnc.org/
CNCLite
CNCPlus
CamSoft
(951)6748100
http://www.cnccontrols.com/
DeskCNCcontroller
seriallportbasedcontroller
IMService
http://www.imsrv.com/deskcnc/
Misc.Software
Deskengrave(free)
ConvertsTrueTypefontsto.dxfdrawings
http://www.deskam.com/deskengrave.html
ACEconverter(free)
Converts.dxfdrawingstoGcode
http://www.dakeng.com/ace.html
Gcodeto.dxfconverter(free)
ConvertsGcodeto.dxfdrawings
http://www.cnczone.com/forums/
opensource_software/8814gcode_dxf.html
LazyCAM(comesintegratedintoMach3)
Basic.dxfdrawingtoGcode.
http://www.machsupport.com/
NCPlot(backplotterforGcodeverification)
http://www.ncplot.com/
CAD(ComputerAidedDesign)Software
AutoCad
AutoCadLT
Inventor(3dCAD)
AutoDesk
http://usa.autodesk.com/
DoubleCADXT
FreeAutoCadLTtypeclone,2d.
http://www.doublecad.com/
TurboCAD
CAMpluginavailable
IMSI/Design
http://www.turbocad.com/
GoogleSketchUp
Free3dmodeler
Google
http://sketchup.google.com/
Rhino3d
3dNURBSmodeler
McNeelNorthAmerica
http://www.rhino3d.com/
Blender
free3dmodeler,lessintuitivethanRhino
http://www.blender.org/
SolidWorks(3DCAD)
DassaultSystemes
http://www.solidworks.com/
CAM(ComputerAidedManufacturing)Software
SheetCAM
2.5dCAM
http://www.sheetcam.com/
CamBamPlus
2.5d,limited3dCAM
http://www.cambam.info/
PhlatScript
free2.5dCAMpluginforSketchUp
http://sketchuppluginreviews.com/2010/04/30/
phlatscriptgooglesketchuppluginreview/
MeshCAM
3dCAM,withindexed4thaxiscapability
http://www.grzsoftware.com/landing/
Cut2d(2.5d)
Cut3d(3d)
VCarvePro(Vcarving,2.5d)
PhotoVCarve(convertsimagestotoolpaths)
http://www.vectric.com/
FreeMILL(freebasic3dCAM)
VisualMill(3d)
RhinoCAM(pluginforRhino3d)
http://www.mecsoft.com/
DeskProtoEntryEdition
simple2.5d,3d
http://www.deskproto.com/
ArtCAMExpress
2.5d,3d
http://www.artcamexpress.com/
ALUMINUM
.1875"x2.50"x2.25"
BEARINGS
(2)3/8"x13/16"x9/64"unshieldedneedlebearings,VXBItem#Kit12703
(includeshardenedwashers)
IforderingfromasupplierotherthanVXB,besurethatthetwo
hardenedwashersareincludedwithbearings.
ALUMINUMorhardplastic,suchasACETAL(delrin)
.375"x2.25"x2.25"
THREADEDSHAFTCOLLAR
Delrinthreadedcollartomatchleadscrewpitch.Source:DumpsterCNC
Alternatively,anunthreadedmetalsplitshaftcollarmaybeused.Hoever,this
willbemoredifficulttoadjustcorrectly.
FABRICATEDPARTS
part# partname #reqd.
46 thrustbearingplate 1
47 zaxismotorspacer 1
LISTOFFABRICATEDPARTS
BILLOFMATERIALS
ThematerialsforthisupgradearenotincludedinthemainBillof
Materialsonpage27.Thesequantitiesshouldbeaddedtothat
primaryBillofMaterialswhenpurchasingmetalstockandhardware.
Requiredis:
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ADDENDUMzaxisthrustbearings
Zaxisthrustbearingaddition:
Thisaddendumcoverstheinstallationofapairofthrust
bearingtotheZaxisleadscrewassembly.Theoriginal
designoftheMomusCNCrouterdidnotincludeathrust
bearingforseveralreasons:theywouldaddtotheoverall
costofthemachine,theyaddtotheheightoftheZaxis
whilepotentiallyreducingitstravel,andrequireproper
adjustmentinordertobeeffective.Asuccessfulthrust
bearingdesignwouldnotonlyneedtosolvetheseissues,
butinkeepingwiththerestofthedesignofthemachine,
wouldalsoneedtoabletobefabricatedwithoutspecial
toolsorequipment.
However,thereareseveralstrongreasonsforincluding
suchbearings.Theyrelievethesteppermotorbearingsof
allaxialforce,whichisbeneficialastheyhavealow
ratingforloadsofthistype.Therefore,externalthrust
bearingswillpotentiallyincreasethelongevityoftheZ
axissteppermotor.Theotherreasonisthatafailureof
thecouplingbetweenthemotorandtheleadscrewcould
causetheroutertoplungeintothetable.Whilethistype
offailureisunlikely,thisthrustbearingupgradewill
provideextrainsuranceagainstthishappening.
Therefore,itishighlyrecommendedthatthefollowing
componentsbeinstalledonMomusCNCrouters.This
upgradeisfullycompatiblewithallpreviousversionsof
themachine.However,onmachinesconstructedfrom
olderversionsoftheplans,itmayreducetheZaxistravel
byapproximately7/16",andwillalsoraisethemotor
verticallyby3/8".Thismaycausecoverinterferenceon
oldermachinesthatusequadstacksteppermotorswith
adualshaft.Athinshimbetweenthecoverandthe
machinebasecanbeusedtoraiseitforsufficient
clearance.
Theassemblysequenceshownherewasphotographed
installingthepartsontoanexistingmachine.The
assemblysequenceisidenticalonanewmachine,only
thegantrywillnotyethavebeeninstalledonthe
machine.Combinetheseinstructionswiththoseon
pages131132.
20Zmotormountright(existing)
21Zmotormountleft(existing)
22Zcableplate(existing)
47Zaxismotorspacer
46thrustbearingplate
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ADDENDUMexplodedview
2.25
4.5
1.125
2.25
0.375
.1875
.438DIA.
.25DIA.,4holes
1.856 1.856
.928 .928
4.5
1.856
1.856
2.25
.928
1.125
.928
2.25
NOTE:
Cutfrom2.50"wideplatestock,asitis
amorecommonstocksizethan2.25"
1.5
1.5
.75
.75
0.5
.25
Slightenlargementofthisnotch
maybenecessarytoallowproper
adjustmentofleadscrew.
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ADDENDUMthrustbearingplate
stocksize:
.1875x2.50
material:
6061T6alum.
#required:
1
2.25
4.5
1.125
2.25
0.75
.375
1.50DIA.
.25DIA.,4holes
1.856 1.856
.928 .928
4.5
1.856
1.856
2.25
.928
1.125
.928
2.25
NOTE:
Cutfrom2.50"wideplatestock,asitis
amorecommonstocksizethan2.25"
1.5
1.5
.75
.75
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ADDENDUMzaxismotorspacer
stocksize:
.375x2.50
material:
6061T6alum.
ORacetalplastic
#required:
1
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ADDENDUMthrustbearingassembly
Theimagestotheleftandrightshowtheadditionallead
screwcomponentsthatarenotshowninthemainplans.
Asshowntotheleft,threadtheDelrincollarontothe
leadscrew,about1.5".Slideoneunlubricatedneedlebearing,
anditshardenedwashers,againstthetopofthecollar.Insert
thisassemblythroughtheholeinthealuminumthrustbearing
plate(part#46).Slidetheotherunlubricatedbearingand
hardenedwashersontothetopoftheplate.
Asshowntotheright,threadthemotorcouplerontotheendof
theleadscrew.Threaditdownthescrewuntiltheendofthe
screwisalignedwiththebottomoftheslotinthecoupler.
Gentlytightenthecouplerinposition.
Asshownintheleftimage,threadthecollarbackupthelead
screwuntilitfirmlycompressesthestackofcomponents
againstthecoupler.Whilekeepingitfirmlythreadedagainst
theparts,tightenitinposition.
Keepthecollartightenedinplace,andremovetheother
componentsfromtheleadscrew,asshowntotheright.
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ADDENDUMthrustbearingassembly
Threadtheleadscrew,withthecollarinstalledperthe
instructionsonthepreviouspage,downthroughtheanti
backlashnut,asseenintheimagetotheleft.Threaditfar
enoughthatthetopofthescrewisapproximately1"below
thebottomoftheZmotormounts.
Asseentotheright,lightlylubricateoneoftheneedle
bearings,andwithitsandwichedbetweenitshardened
washers,slideitdownthescrewontothecollar.Alight
lithiumgreasecanbeusedforlubricant.Becautioustonot
useanexcessiveamount,thatwillgetontothesurfacesof
thecollar.Thecollarshouldbekeptclean.
Asshowntotheleft,temporarilyinstallthealuminumbearing
platewithoneortwoofthe2.5"screws,andplacetheother
lubricatedbearingandwashersonitstopsurface.Makesure
itsboreisalignedovertheholeinthebearingplate.
RaisetheZaxisassemblyup,sothattheendoftheleadscrew
isguidedthroughtheholeinthebearingplate,andthroughthe
bearing.Whileholdingitinthisposition,threadthemotor
couplerontotheendofthescrew.Threaditdownthescrew
untilitisfirmlyclampingthebearingsandplatetothecollar.
Thistightnessisthepreloadsettingonthebearings,and
shouldbetightenoughtoremoveallslack.Maintainthe
couplerinthisadjustment,andtightenitsclampingscrews.
Removethetemporaryscrewsholdingthebearingplatetothe
motormounts.
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ADDENDUMthrustbearingassembly
Setthenewmotorspacer(part#47)ontopofthemotor
mounts.
Setthecableplate(part#22)ontopofthemotorspacer.
Placethesteppermotorintoposition.CarefullyraisetheZ
axisassemblyup,sothatthemotorcouplerisguidedonto
theendofthemotorshaft.Besuretocarefullyalignthe
flatonthemotorshaftwiththesetscrewinthecoupler(see
page131fortheadditionofthissetscrewtotheDelrin
coupler.)Itmaytakesomewigglingtogetthecouplerto
slideontotheshaft.
Installthefourscrewsthatholdthemotortothemounts.
Tightenthemsnuglyinplace.
Fullytightentheclampingscrewsonthecoupler,sothat
themotorshaftissecurelyheld.Tightenthesetscrew
againsttheflatonthemotorshaft.
Duringthealignmentproceduredescribedonpage164,
veryslightlyloosenthefourscrewsholdingthemotortoits
mountssothatthemotorcanberepositionedsidetoside
forproperleadscrewadjustment.Fullytightenthescrews
afterthisprocess.Donotloosenanyoftheclamping
screwsonthecouplerorcollarduringthisprocess,orthe
bearingpreloadadjustmentmaybelost.
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ADDENDUMthrustbearingassembly
Theneedlebearingsthatareusedareanunshielded
design,thatmustbeprotectedagainstdustandcutting
chips.Thelowerbearingcanbeprotectedbymerely
wrappingalengthofPVCelectricaltapearoundthe
circumferenceofthecollar.Carefullysetitsothatitjust
lightlycontactsthebottomsurfaceofthebearingplate.
Theupperbearingcanbeprotectedbysimplyclosingoff
thefrontofthecavityinwhichitsitsbetweenthemotor
mounts.Thiscanalsobedonewithtape,asshowntothe
right,orablockoffplatecanbefabricated.
Afterclosingoffthecavity,reinstalltheZaxislimit
switch.Thelimitswitchplacementwillneedtobe
adjustedfromwhereitwouldbeplacedifnothrust
bearingswereused.Thismaymeanonlyonescrewwill
securethebracketthatisincludedwiththeseplans.