Rails and Frame (May 17)
The weather got nice and my many other hobbies pulled me away.
This last weekend I picked up the aluminum and steel I needed for the Rails and Frame. I am using 1/4x 3 aluminum for the rails and 2X2 .188 wall for the frame. All is 5 foot long but the gantry will need to be shorten to 4 to fit inside the y axis. I changed this to give the Z more travel. (see more on gantry build) The extra foot on the y is to allow the full use of the 4x4 cutting deck.
So the aluminum get mounted on the steel with drilled and taped holes on center and spaced out.
This last weekend I picked up the aluminum and steel I needed for the Rails and Frame. I am using 1/4x 3 aluminum for the rails and 2X2 .188 wall for the frame. All is 5 foot long but the gantry will need to be shorten to 4 to fit inside the y axis. I changed this to give the Z more travel. (see more on gantry build) The extra foot on the y is to allow the full use of the 4x4 cutting deck.
So the aluminum get mounted on the steel with drilled and taped holes on center and spaced out.
- (Fig 1) I almost went with. My change to this would have been without the nema mount and mount the screw mount.
- (Fig 2) This is cast your own using lost foam . Where this is a great design spare parts... it was just too much for me
- (Fig 3) Good thought but I didn't think it would hold up.
- (Fig 4) I liked this but the cost of the rails put me off.
- (Fig 5) this is very close to what I planning. I haven't order anything from http://www.cncrouterparts.com but If I did not have the tools to cut my own, I believe I would start here. If they ever go to ball screws, I think that will capture the DIY market. The last I looked they also have the best price going that shows you what you are getting. Everything is show on their site to include the build sheets. To do it again I think I would make what I can easily and buy the hard to build parts from them.
My Rails are using 2x2 .188 steel and 1/4 x 4 aluminum
The rails are going to use steel and aluminum. The steel to make it strong and the aluminum will be used for the carriage to ride on. All this was bought at Shapiro Metal supply (https://www.shapirosupply.com/). If you can get there you'll find a lot of things you didn't know you need. I have some of that stuff, on the other had I gotten some great deals.
I still have to trim the steel. When they cut these it was measured with a tape rule, marked with chalk, and cut with a friction saw.
On the ends I will weld caps/mounts. This will bolt to cross arms to tie the left and right together. Linking the left and right together has e thinking hard. I want to leave room for a water tray to be put into place. I don't want what to used to hold it together to get in the way. When the water tray is in place I need a way to lock the two together. Oh, and the hold thing can't move when the cutter is moving. One step at a time while looking ahead four steps.
I still have to trim the steel. When they cut these it was measured with a tape rule, marked with chalk, and cut with a friction saw.
On the ends I will weld caps/mounts. This will bolt to cross arms to tie the left and right together. Linking the left and right together has e thinking hard. I want to leave room for a water tray to be put into place. I don't want what to used to hold it together to get in the way. When the water tray is in place I need a way to lock the two together. Oh, and the hold thing can't move when the cutter is moving. One step at a time while looking ahead four steps.
Broken Taps
I got the rail drilled and needed to tap them. As luck goes, the first three holes I broke off two taps. I would love to say it was cheap hf crap but these were good ones. In both cases the tap broke off flush. A good video to watch to see how to remove broken bolts: (https://www.youtube.com/watch?v=jnF9_LotHCU). Well you'll get a good laugh.
The best way I have found to remove broken bolts, taps, pins, and thing... Get a TIG, set it at 50to 60 Amps, then heat the center. When you see it start to melt put a drop of weld rod on it. Let it cool a little and then do it again. repeat this until it is ready to grab with your vice grip. If it gets to hot stop and let it cool. Now you have something to grab. Take it slow and move it back and forth.
The best way I have found to remove broken bolts, taps, pins, and thing... Get a TIG, set it at 50to 60 Amps, then heat the center. When you see it start to melt put a drop of weld rod on it. Let it cool a little and then do it again. repeat this until it is ready to grab with your vice grip. If it gets to hot stop and let it cool. Now you have something to grab. Take it slow and move it back and forth.