The three hardest parts of building this router, so far, has been:
1. Preparing the frame. This includes the 32 holes I had to tap in the bottom of the legs just to bolt on the castors. Plus, all the boring of holes for the butt-joints and other T-slot connectors.
2. Mounting the big THK rails on top of the T-slots frame.
3. Drilling out 40 precision holes in the racks for the rack-and-pinion drive. The racks don't come with holes because they don't know how your going to mount them. I had to start with a 1/8" hole and work my way up to 5/16. So each hole got drilled about 4 times. 4 racks, 10 holes per rack, drilled 4 times each = about 160 times I had to drill.
anoel:
I know who "Twisted Sister" is, but I can't say I'm a fan really. Why do you ask?
Ynneb:
Yes, in case your wondering about the name "Captain Howdy", it was the name of the demon that Regan talked to through her Ouija board in the the movie the Excorcist. I thought it an only appropriate since this router was a devil to make and I plan on making some Ouija boards with it. It just sounded better than the obligatory "Mr. Chips", LOL.
