I'm finally getting around to building a new router.
I've previously built one of my own design which had 900x375mm cutting area. It was based on SBR16 rails with ballscrews (single screw on X). Made of 25mm plywood and aluminium extrusion. Unacceptable flex and racking, I've never been happy with it.
So after plenty of reading and research, I've come up with my replacement design.
I was initially going to bolt everything together and painstakingly level. I've since bought a welder and will be using that.
Design:
Welded steel construction
Dual drive on gantry
Cutting area of greater than 1220x610mm (quarter sheet) - will be ~1250 by ~650mm in reality
Travels ~1250x675x200mm
Self levelling epoxy for rail mounting (probably West System 105 + 209)
Linear profile bearings
- already have 830mm long 20mm rails for the Y axis (short axis)
- 15mm new Hiwins for X (long axis, 1500mm along gantry) and Z axis
15mm ground ballscrews with 20mm lead for Y axis (already have)
16mm rolled ballscrews with 16mm lead for X and Z axis (new, SFE1616)
I have decided to go for a wide machine, with the gantry running the longer axis for two reasons:
1. It works better in the vast majority of spaces as it can be loaded from the front.
2. I already have a very nice pair of ground 20mm lead ballscrews with great bearing blocks.
The steel gantry will be stiffer than 3060 8020 used in CNCRP machines, and I believe will be adequate.
Maximum workpiece height is ~100mm
The Z axis travel has been designed to reach the table with 20mm tool stickout, and to clear the top of a 100mm piece of work with 80mm of tool stickout. The spindle will be adjustable up and down if I need to work with very short tools or very long tools.
Overhang over front of machine for vertical machining (65mm thick pieces) and a 4th axis (should be able to machine 150mm diameter by ~1m long)
The table top will be a layer of ~30mm MDF covering full area, with T slots and Tee Nuts, then another ~18mm piece same size as cutting area as sacrificial board.
The steel:
Large Y axis rails are 200x200mmx6mm RHS.
The Gantry is 200x200mmx6mm RHS with an unsupported span of ~1400mm.
The bearers under the table are 150x50x3mm RHS
I'll likely put a strap joining the bottom of the bearers to box it all up.
Without the stand, it looks like the machine will weight >160kg (352lb)
I've previously built one of my own design which had 900x375mm cutting area. It was based on SBR16 rails with ballscrews (single screw on X). Made of 25mm plywood and aluminium extrusion. Unacceptable flex and racking, I've never been happy with it.
So after plenty of reading and research, I've come up with my replacement design.
I was initially going to bolt everything together and painstakingly level. I've since bought a welder and will be using that.
Design:
Welded steel construction
Dual drive on gantry
Cutting area of greater than 1220x610mm (quarter sheet) - will be ~1250 by ~650mm in reality
Travels ~1250x675x200mm
Self levelling epoxy for rail mounting (probably West System 105 + 209)
Linear profile bearings
- already have 830mm long 20mm rails for the Y axis (short axis)
- 15mm new Hiwins for X (long axis, 1500mm along gantry) and Z axis
15mm ground ballscrews with 20mm lead for Y axis (already have)
16mm rolled ballscrews with 16mm lead for X and Z axis (new, SFE1616)
I have decided to go for a wide machine, with the gantry running the longer axis for two reasons:
1. It works better in the vast majority of spaces as it can be loaded from the front.
2. I already have a very nice pair of ground 20mm lead ballscrews with great bearing blocks.
The steel gantry will be stiffer than 3060 8020 used in CNCRP machines, and I believe will be adequate.
Maximum workpiece height is ~100mm
The Z axis travel has been designed to reach the table with 20mm tool stickout, and to clear the top of a 100mm piece of work with 80mm of tool stickout. The spindle will be adjustable up and down if I need to work with very short tools or very long tools.
Overhang over front of machine for vertical machining (65mm thick pieces) and a 4th axis (should be able to machine 150mm diameter by ~1m long)
The table top will be a layer of ~30mm MDF covering full area, with T slots and Tee Nuts, then another ~18mm piece same size as cutting area as sacrificial board.
The steel:
Large Y axis rails are 200x200mmx6mm RHS.
The Gantry is 200x200mmx6mm RHS with an unsupported span of ~1400mm.
The bearers under the table are 150x50x3mm RHS
I'll likely put a strap joining the bottom of the bearers to box it all up.
Without the stand, it looks like the machine will weight >160kg (352lb)
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