I built my first router back in october of 2007. It was built specifically to help out with a large production job i had at the time. Luckily i got the machine up and running with very few issues, but there were always some weaknesses in the design.
I've been running the machine weekly since that time, and finally have a break in my work which should allow me to fix some of the issues.
two things i'm going after.
1. Gantry rigidity. I largely underestimated the impact of cutting forces. The gantry was fabricated out of 3/4" pvc due to its price and its machinabilty. Poor choice for obvious other reasons.
2. Travel speed. I'm stuck at around 80ipm
Here are some pics of the current build. I will be keeping the base, which is very sturdy and welded up out of 2"x2" angle iron. Underneath are two VXB 25mm linear rails for Y axis
Plans are as follows..
One.
Keep the same machine layout and design concept. Replace / rebuild entire gantry out of extruded aluminum channel.
for the plate that connects the Y axis bearings under the table, i will use 2.8" x 10" x .5" aluminum channel.
On either end will be 1/2" or 3/4" 10" wide aluminum by about 18" tall.
From there i will mount a piece of 2.5" x 8" x .5" aluminum channel vertically where the X axis linear rails will mount.
I will also use some of the left over 10" wide aluminum to made the trolley for the router.
example of the channel
Two.
Switch out the X axis linear rails to 60" lengths to give me an X travel of 49" (verses 44" i have now)
Three.
Switch out my 1/2-10 2 start screws for 5 start to help improve my IPM's.
I just ordered the aluminum today, so hopefully things will be underway shortly i can post back up some progess.
Please let me know your thoughts / comments on this!
thanks