I figured I would start my own build thread since I am quickly gathering a ton of pieces to this. I ordered my kit from Joe about a week and a half ago (Joe is it done yet? :stickpoke LOL). I stopped by Dave's (HobbyCNC) and picked up my 3 axis kit. Luckily I only live about 15 minutes from him. I have ordered all of the hardware and most of it is in. Picked up the last few pieces from McMaster today (another place that is close by), the aluminum angle and all the threaded rods. I think the only other parts I am waiting on are the transformer and the router. I assembled most of the HobbyCNC board over the weekend and just need to do the 5v test before finishing it up. In the meantime I need to build the guides. I have about zero metal fabricating experience, so this should be interesting. My question right now is how to cut the aluminum. Can I use my table saw or compound miter saw? I have a drill press to drill the holes and read about using a stop block to get them all the same. I do the same thing in my acrylic business, so that I understand. I have just never really worked with aluminum before. Any tips would be great.

Overall, I am pretty excited about this. I plan on using the router to do a lot more acrylic fabricating and to expand my business beyond just the laser cutting I already do. The laser has it's limitations, and I have always wanted a cnc router anyway. :)

-Paul

Welcome aboard. You can cut the aluminum with a bandsaw (metal blade of course), table saw blade (carbide is a must but be careful), cut off saw or people have even put metal cutting blades in their chop saws. I used a band saw but cut many of my metal parts like the acme rods and drill rods with a cut off wheel on my circular saw. They are cheap at home depot, about $10.

I was trying to find the post that someone here in the cnc model 2006 section showed how they used their table saw with a jig and worked real good.

I have a cross-cut sled for my table saw and read that the Freud Diablo 40T worked pretty good for cutting Al. I might give that a shot. I could probably use the same blade in my CMS too. Maybe I need to go buy a band saw! LOL

A table saw will give you much better results than a bandsaw. The miter saw will work fine too. Use a triple chip blade, if you have one. Negative hook is even better. Use the crosscut sled, and go slow, with a sharp blade, and you'll be amazed at how easy it is to cut.

That's what I use to cut all of my acrylic; TCG, 90T blade. Expensive, but gives me a good cut. I have several of them, so I will give that a try.

Thanks!

You were right Gerry. That TCG went right through it no problem. Nice clean cuts too.

Quick update.

Got the router yesterday (Hitachi M12VC, nice compliment to the Hitachi M12V that has been in my router table for 3+ years)

Got the transformer to build the power supply for the HobbyCNC board.

All the other parts are in.

Aluminum angle is cut, just need to drill the holes and I can assemble the slides.

What size table is everyone building for these? I can get that done while I am waiting to receive the parts from Joe.

Quick update.

Got the router yesterday (Hitachi M12VC, nice compliment to the Hitachi M12V that has been in my router table for 3+ years)

Got the transformer to build the power supply for the HobbyCNC board.

All the other parts are in.

Aluminum angle is cut, just need to drill the holes and I can assemble the slides.

What size table is everyone building for these? I can get that done while I am waiting to receive the parts from Joe.

Sounds like you're on your way to having a joe machine. I built a kind of low bench because I wanted my machine at waist height so there was no bending over or reaching up to get at it. Made it out of poplar and 1/2" mdf top. As a tip make a cutout in the middle so you can access it later from the bottom to grease or access the anti back lash assem on the bottom without taking the thing apart.

http://vi01.com/cnc/20.jpg
Thats my bench in the early stages. David got a good deal on a table on I think buy.com, it's pretty nice looking.

What are the dimensions of your table? Looks like just the right size and I agree about the height. I want the top of the router to be at a comfortable height as well. I don't want a sore back after a day of using it! :D

About how many cans of Kilz is everyone using to prime all the MDF parts? I'm wondering if I would be better off ordering a case online then buying the individual cans at HD or Lowe's.

About how many cans of Kilz is everyone using to prime all the MDF parts? I'm wondering if I would be better off ordering a case online then buying the individual cans at HD or Lowe's.

Paul,

Looks like you are off to a good start! Can't wait to see pictures of your progress.

I think I ended up using around 7-9 cans of primer (gray) so it would be easier to tell how good I was covering with the white. Used about 10-12 cans of white.

My table was built from a kit I purchased at Rockler. It is a bit to high with the casters on it so once I have it in my garage I'll use the orginal bolt type feet that came with it. Right now the work surface is at about 50 inches.
I want to end up with at about 42 to 44" to make it just right for me. :)
The frame I purchased when assembled is 36"d x 42"w. With the top I have about 8" inches at each end of the machine whick gives me a place to set tools and so on.

Bob

Not much has happened lately. Just waiting on the kit to arrive. :) I did go ahead and order 1/2"-8 2 start and AB nuts from dumpsterCNC. I am returning the 1/2"-10 as I think the 2 start is the way to go from everything I have read. I guess I need to order new nuts to fit the new rod correct? Or would using the Dumpster thread clamps be the better way to go?

For those of you using the Igus e-chain, how long are the pieces you are using on each axis?

Anyone? I know people are using cable carriers. :)

I'm in the Cincinnati area were are you in Ohio? Not building Joes kit yet but have been doing a little CADs based on Joe's and Lionclaw drawings.
As for cable holder length think most just guessed at the amount needed and added more could be drawn up.
Lonnie

I'm just east of Cleveland. I am looking for the people that have cable carriers installed already so I have an idea of how much to buy. =)

I think david and Buzz used it may want to send them a message.

Joe

I'm just east of Cleveland. I am looking for the people that have cable carriers installed already so I have an idea of how much to buy. =)

Paul,

Do a search of David Da Costa's log for "Igus". He gives the lengths that he used.

Bob

Thanks Bob, that is what I needed.

For anyone else looking here is what I found:

X axis - ~58"
Y axis - ~34"
Z axis - ~24"

-Paul

I don't have the measurements for each access but I did mine with 10'. I could have done it with a lot less because you really only need to start the Igus at the half way point the rest will just sit still all the time but it sure looks clean with it all contain across the entire axis. I was about 10" short of have a perfect full length for the z axis.

That sounds about right. 2 feet for the Z, 3 feet for the Y and 5 feet for the X. So 120" should be plenty. :) Thanks

Well, the kit is going out today. Can't wait to get started!

Got everything yesterday. DHL was pretty brutal with the box, but everything made it in one piece (nice packing job). But holy packing peanuts! Everyone wasn't kidding about these things. One suggestion, use the pink anti-static peanuts. It would make cleaning them off a lot easier. :)

Got everything yesterday. DHL was pretty brutal with the box, but everything made it in one piece (nice packing job). But holy packing peanuts! Everyone wasn't kidding about these things. One suggestion, use the pink anti-static peanuts. It would make cleaning them off a lot easier. :)

Glad it made it there ok, they always handle the things rough.

I will look into the pink ones, my nija's are white... (pink a little girly)... LOL

also do you happen to have a USMC logo in 3D? like to cut it out for a friend.

Joe

Yeah, they are pink, but they don't stick to everything. :)

I don't have a 3D version of the USMC logo, but if you find one please send it to me!

holy packing peanuts! Everyone wasn't kidding about these things. One suggestion, use the pink anti-static peanuts. It would make cleaning them off a lot easier. :)

I think it's more of an initiation ritual :)

I think it's more of an initiation ritual :)

Good one :)

Congrats on getting your kit. Hopefully mine will be on the way soon. Like you I have all my parts and pieces together.

Keep us posted on your build.

Gene
SFC(R) US Army.

Congrats on getting your kit. Hopefully mine will be on the way soon. Like you I have all my parts and pieces together.

Keep us posted on your build.

Gene
SFC(R) US Army.

I second that! Congrats Gene! Can't wait to see you and GTGene in action!
Very exciting to see all the new builds and the new ideas that spring up from them!

Bob

Here is a quick V-Carve Pro, and the DXF file for you, I'm still looking for better and also 3D.

Joe

I think that might have to be my first cut using your machine Joe! :) I'll keep looking for a 3D version for you as well.

Hey Joe. I found this thread over on the VCarve forum that has a 3D USMC logo that might work for you.

http://vectric.com/forum/viewtopic.php?t=1572

-Paul

Semper Phi fellow Marine MCRD was were I was Born 93-2000 Okinawa, Japan to the lovely 29 Palms, Ca---

Glad you have your kit that must mean I'm next to recieve mine Yeah I can't wait.....and yes the first project I want is the 3d marine logo...OOOOOOOOOOOOOOOOOOOOOOOOOOORRRRRRRRRRRRRRRRAAAAAAAAAAAAAHHHHHHHHHHHHHHHH.

No kidding? I was in from 93-99. Spent a year in the stumps in Comm school then off to Lejeune for 5 years in 2nd MarDiv. Almost all of that time was with 2/4 and 2/6.

Semper Fi Marine!

Fade what electronics are you using

HobbyCNC. Dave lives about 10 minutes from me so it was a no-brainer as I could just go pick it up.

Just a quick update.

1. Got the Z carriage built and primed.
2. Almost all of the gantry is glued up, but needs to be primed and assembled
3. Fit together the bottom torsion box. Looks like an exciting glue up on that!!
4. Joe is cutting some new AB blocks for me to fit the dumpster anti-backlash nuts with the flange for the 1/2"-8 2 start I am using throughout.
5. Received all my cable carriers I got off eBay (great source for cheap one's if you're looking)
6. Received my ATC parts from High Tech Systems.
7. Received the 1/4" collets from Enco for the ATC
8. Got the PC rebuilt and the new monitor came in.
9. Trying to reorganize the shop as well to make room for this as well as improve the work flow in there.

Won't get much done the rest of the week as I am out of town. So far it is coming along slowly, slower than I had hoped but that is just due to lack of time. Darn customers keep ordering stuff from me and cutting into my cnc build time! :)

Sorry no pictures yet, trying to dedicate the time I have to getting it built.

Sounds as though you are making great progress and going in the right direction. I'm happy people have been fairly vocal about their modifications with joes06 machine because many people are avoiding previous hardware and going straight for the good stuff saving a ton of money and time tinkering.

Been a while since I posted an update. My business has been so busy I haven't had much time to devote to getting this router done though. I finally got caught up about a week ago and have devoted some time to getting this finished. And then the big "Oh S$#%!". I was assembling the big bottom torsion box this week. Last night I was putting on the MDF skin on one side and noticed that I had glued in 2 of the cross members backwards! I didn't even notice that they stuck out different amounts on the sides! So now I am stuck. Is there any way to fix this or should I just email Joe (or some other nice person whom I will gladly pay)and get him to recut all the pieces for me for the bottom? I was so disappointed because I was finally making good progress on this thing. Oh well, I can still keep working on other things until this debacle gets fixed.

Howdy fade2black,

Sorry to hear about your misfortune. You might be able to hand cut the long side to match the short side and maybe someone can cut you a piece of the long side from the outside of the x axis to the pipe recess . that way you can glue it right over the short piece and if you had two made for each you good sandwich it with the short piece in the center. I hope you understand what I am saying if not I will try draw it. I think this fix would work or at least enable you to complete your build and cut your own …. Just my 2 cents on the matter..


Good luck

Kent

Sorry to hear about the problem. There are two things you can do. But first break it apart. You should be able to save one of the two parts. If you didnt finish gluing use one of the parts as a template. Cut out leave a 1/16th-1/8th and clamp it down and rout the rest with a flush trim bit. Second option is to get those parts cut again. If you can manage to save the rest and just lose the ones you put in wrong, then you aren't in bad shape. Joe could probably cut the parts for you since a few ribs isn't that much work but if he is busy shoot me an email and I can cut them for you by this weekend.

Sorry to hear about the problem. There are two things you can do. But first break it apart. You should be able to save one of the two parts. If you didnt finish gluing use one of the parts as a template. Cut out leave a 1/16th-1/8th and clamp it down and rout the rest with a flush trim bit. Second option is to get those parts cut again. If you can manage to save the rest and just lose the ones you put in wrong, then you aren't in bad shape. Joe could probably cut the parts for you since a few ribs isn't that much work but if he is busy shoot me an email and I can cut them for you by this weekend.

I think the best bet is to just rebuild it. Do it right the first time :) I emailed Joe earlier today and haven't heard back yet. If I don't hear from him by tomorrow night I'll PM you. Thank you very much for the offer too!!

-Paul

I have some extra ones and the other parts, send me an e-mail will all contact info and i will send out friday.

Joe

Email sent. Thanks Joe!!!