Thanks for the welcome guys. I checked out the spreadsheet and it helped a lot.
I don't have pics uploaded yet, but I have most of the woodwork done. I built the z-axis box and both of the y-axis boxes a couple days ago. I glued up the x-axis torsion box today. I find that the fit of the parts is so precise that the assemblies are virtually self-jigging.
I used the .5" MDF for the x skins as others have. That is one strong box. I had the HD guy cut them for me on his big saw, and even though the sign said "NO precise cuts!" I asked him to get it as close to 24" as he could. He nailed it, and the parts snapped in place.
To make the box, I laid one skin on the worktable, and glued and clamped one cross piece in. Then I glued the long pieces in, and then worked back gluing the rest of the cross pieces in. As long as the skin is square, you're almost guaranteed a square box this way because the parts fit so tight.
I finished the extension pieces and then glued the top skin on. I'm using polyurethane glue. The only thing I don't like about it is the way it foams up out of the crevices. It seems to wet the MDF pretty well though.  |