Solsylva 25x25 Router

[npow]

Well this week I finally decided to move forward and build a Solsylva 25x25 router. I'm been lurking around here for a month or so trying to learn the lingo and settled on the Solsylva plans. I'm not a very skilled DIYer, so this is going to be my jump into the deep end of woodworking, CNC, etc.

I am somewhat budget conscious since this is strictly a hobby build and I have no idea if I am in over my head - I have no experience with CAD/CAM or electronics. I want to do this project so I can learn new skills - and I am sure I'll have plenty of questions along the way. I also don't expect this to be a fast build since I have two young children, but I started this post so I could feel somewhat "accountable" in working on the project!

I don't plan on any modifications to the design besides upgrading the leadscrews at the beginning, because I don't feel confident enough at this point. This week I started collecting parts around town and ordering a few - today I received my leadscrews from McMaster (3/8-8 4 start).

Today I went out and cut all of the pieces for my table stand. I also picked up a drill press that I got for a steal from Sears. I hope to start assembling tomorrow and then I'll work on the bed next. I'm using southern yellow pine for the stand and bed, and probably a mixture of woods, to include some red oak, for the router itself.

Here are a couple of pictures (excuse the poor quality iphone pictures) to kick start my build... just a few of the cuts for the stand and the freshly assembled/untested drill press.

Nathan

[npow]

I have made some progress over the holiday weekend - Happy New Year! The stand and the base for the router have been completed, per the plans - square and level...

I've moved it into it's future home, where you can see the old PC I have already set up. No electronics yet, as I haven't decided what route to go.

The next step is assembling the rails for the x axis... I have some cut black pipe that is sitting in the vice ready to be measured and marked for drilling.

[npow]

Made some progress on the rails, but I ran out of threaded rod so I only completed one.

[npow]

I've been busy lately with the family, so not much time to work on the router, but I have at least finished the X axis rails and mounted them on the stand. I have also worked on the Y gantry a little. Today my electronics showed up (I bought the 3 axis gecko 540 kit from cncrouterparts) and so I spent a few minutes wiring everything up to make sure I could figure it out... success!

I have several more components on order, including my enclosure, so I just did a quick test and then put everything up. I was excited it worked, though!

Here's a quick, boring video, but everything moves and the e-stop works. Sorry if the video is a bit shaky; the iphone requires some really steady hands!

[CNC Lurker]

Congrats, getting the computer to talk to your steppers is an important step (no pun intended).

Just a heads up, not sure if Ahren has corrected the resistor-in-the-wrong-place problem or if you haven't seen the thread about it yet, so you ought to read this thread:
Important Gecko 540 info - news to me!! LINK

[npow]

Thanks for the heads up - I did see the thread.

The cables from the steppers are fully molded, so I don't want to chop anything up at this point. I believe I am going to wait until I have everything built and tested to see if I have any issues.

[npow]

So I am going to slowly revive my thread (almost a year later)... we'll see how long this lasts. I did continue to work on the router in the months after what I have already posted, mostly completing my electronics and the x axis (see attached pictures). I also got that drill press up off the ground - what a relief!

I think I have some more work to do on the electronics, because when I look at my pictures I don't have the plug/relay wired up - or maybe I do and just didn't take a picture! I plan on cracking the box open and checking soon!

So after my spring/summer/fall break, I did finally finish the carriage for the y axis and get it mounted/tested. I've embedded two videos - one from several months ago running the x axis, and one from tonight running the carriage back and forth.

In the second video, you'll note I am just jogging the carriage and not the x axis, too. That's because when I was running it through its paces I managed to cause the left side of the gantry to become detached from the leadnut/leadscrew - I guess some of the nuts became loose over the hiatus! I did finally fix it, but by then it was time to come in and help get the kids to bed!

Next step is the z axis. Hopefully my pace of one axis per 6 months won't hold true and I will be back before long updating my status!

Anyways, enjoy!

Nathan

http://www.youtube.com/watch?v=pYNgT_XDpcA&feature=mfu_in_order&list=UL]Solsylva CNC Build - X Axis Test - YouTube

http://www.youtube.com/watch?v=CI98Csf09S8&feature=mfu_in_order&list=UL]CNC Router Carriage Test - YouTube

[npow]

So I went a bit quicker than expected and actually managed to cut some wood! I didn't take a picture of the results, but they can be seen clearly in the video below - it's a simple v carve of a tiger eyes logo from Auburn University.

I have a few issues to work out, such as trying to figure out what to do about the table it is on. I never was a big fan of the design, and it just really isn't sturdy enough. I had to run the speeds way down because the whole machine would shift when abrupt direction changes were made. My biggest issue is space (not giving up my parking space in the garage!)

I also need to work on my wire management (to include running wires for and installing limit switches). I've been purusing the forums trying to get ideas, but I haven't quite settled on how I want to handle it. Part of my issue is I don't have a permanent location for my electronics - they need a better, more permanent spot than on my workbench.

http://www.youtube.com/watch?v=tfdpNXSMTGE]Solsylva CNC First Cut! - YouTube

[CarveOne]

Nice job! The first cuts (that go right ) are always what makes months, and sometimes years, of building a machine finally worth the effort. Have fun with it.

CarveOne

[npow]

Thanks - that first cut did go well... my second was close! I didn't have the chance to take a picture, but I think I had my x-axis flipped (mirror image!). I was cutting a letter - my wife said to cut something useful for her - so I am going to attempt to cut some letters of our youngest childs name out! The first test run produced a useable letter, except for a couple of "bumps" on one side. I'll try to post the picture later so I can get some advice as to what the issue might be.

[npow]

So here is the little letter "a" I cut. A couple of small "bumps" on the left side. I think I am going to remove the router from its base and put it on the floor and see if the firmer concrete floor makes a difference - then make a new stand for it.

On a separate issue, the idler on the belt drive axis busted. One picture shows it installed, with two noticable "bumps" where the bearings are just a tab too big for the coupler that was used to make the idler. The first issue was that it helped force the belt to rub against the wood... not sure the long term issues this could create. The next picture shows what happens when a piece of stressed coupler get stressed even more by overtightening the nut that was holding it all in place. Time to visit Lowe's.

The next pictures show a partial, hopefully temporary setup to manage my cables - a long piece of flexible plastic normally used for building a screened in porch :-) Currently, the wires are being held in place with twist ties normally found in a garden for tomato plants. The plastic is actually pretty nice because it has a couple of "channels" for the wires to travel in.

I also need to install a new circuit in my garage... can't seem to run my heater, lights, router, computer, Christmas lights (yea, the outside outlets run on this same circuit as well), etc. without ending up working in the dark! Now if only I could find the time to work on all these projects, plus wrangle three kids under 4! :-)

Nathan

[CarveOne]

Those bumps look like they may be in the CAD file and the gcode is just following it. Check the drawing file in those areas and zoom in to see if there is an angular change in the curve .

CarveOne