BobL's Rockcliff build

[boblon]

Well I've finally started building. I know I've asked a lot of dumb questions here already, but I don't see that stopping anytime soon now that I've begun to build

I'm following the Rockcliff plans, albeit not too closely as I'm adjusting to suit the parts as I go. I've finally got most of the parts I'm going to use in hand but still am waiting on AB Nuts from Dumpster CNC.

It's an MDF first time build by a real noob so we'll just have to see how it comes out.

I'm using 1/2" X 10 TPI Acme lead screws. I've got Nema 23, 282 oz motors from Keling and thier KL-5042 drivers to go with them. I also got thier KL- 3815 PS (500 W, 38VDC/15A) and a BOB. Oh yeah, got a Mach3 license from them too.

John from Keling is a great guy to deal with.

I know those drivers and PS are probably more than I need right now, but I figure this first machine is just to get my feet wet. I'd really like one that will cut close to 24" X 48" so hopfully I'll only have to replace the motors if need be.

Anyhow, it's good to finally be building, hopefully it will do SOMETHING and I won't have to start all over before I can make any sawdust with it

I'm sure I will have more questions and I appreciate all the help you guys have already given me.

For now, back to the garage, breaks over.

BobL.

[boblon]

Still going strong.

I had ordered my Acme lead screws from EBay and it wasn't untill after I purchased them that I realized that they were only 30 minutes from me. So I went and picked them up. When I was down there I asked them about thier aluminum motor mounts. They said they didn't have any and only worked on them when they had time between other jobs.

Well I called them this morning to see if they had any per chance. Not only did they have some, the guy said I was lucky to find them there as they don't usually work on Saturdays. So, bottom line is I've got the motor mounts too.

When I got back I checked my mail box and lol-and-behold, the AB nuts were here. After 1 false start and 2 orders that shipped with incorrect parts maybe things are finally going my way (unless of course I just jinxed it) .

I had already built the torsion box base while waiting for parts to arrive and I'd really like to get the Y-Axis done today, although it's starting to get late on me.

I will try to post some pics of my progress later this evening.

BobL.

[boblon]

Well, I didn't get as far as I would have liked, but then, I never seem to.

The table is not yet mounted and the Y rails are only tacked down so I can make final adjustments and verify the table moves from one end to the other without binding.

But so far I'm fairly pleased with how it's coming along. Pictures aren't that great, I'm not much of a photographer, but then again it could be those 3 pots of coffee I've had today



BobL.

[dz1]

build is looking great, you have chosen a nice collection of upgrades. I am about ready to start my second machine and the linear rails/bearings and upgraded screw were on the definate list of things to add. The motors mounts are slick too nice to be able to adjust the coupling without dismounting the motor. Cant wait to hear how it cuts

[boblon]

Ok, lesson learned. LOL

When dealing with TKO style linear bearings DO NOT just slide the carriage off of the rail....DAMHIKT !!

What a PITA.

Luckily I found all but a couple of bearings. I hope it will be alright...geeez.

BobL.

[boblon]

Gotta quit for today. Got quite a few things figured out as far as how I'm going to do the Z-axis. Up until today I wasn't really sure how I was going to do it.

Several trips to the hardware store really drove home how a project like this can nickel-and-dime you to death. Amazing what small metric cap screws cost. I'm sure I could have got them cheaper on line but I wanted them now and I don't mind feeding the Mom-n-Pop H/W store down the street, keeps 'em in buisness (and handy for me).

Nothing I've done today is bolted in it's final positon, just clamped up to do trial fits and measurments. I am very happy the Z-axis is coming together, I was a little worried about that.

Anyhow here's a few more pics.



Thanks for looking,
BobL.

[boblon]

Haven't had a lot of time the last couple of days to work on my machine, but some.

I've been working on tyring to get the table rails firmy secured and aligned. Having problems getting all of the binding out. I may remove them and try a different method of installing/aligning them. I really want to get going but this is gonna hold me up until I fix it.

I have also been doing a little more work towards getting the Z-Axis going. Still more work needed there.

I expected a few problems so I can't say I'm surprised.

BobL.

[boblon]

I spent some time at work thinking about what to do about the table rails.

I had pretty much decided to remove them when I got home and try a different way to mount them. However, when I got home I went out to the garage to mull over the situation a little and move the table back and forth.

It seemed to move a lot better than I remember leaving it last night. Of course I had spent a couple of hours fussing with it and was getting a little frustrated when I left it.

Anyhow, did a little more fussing with them and I think I will leave them alone for now. They are not perfect, but they might just work. I may have to tweak them a little later, but for now I've decided to proceed with the build and when I'm done banging things around and get the rest assembled I will take another look at them then.

Bottom line is I might just be back on track (so to speak). I did a little more work on the Z-Axis assembly, stopped as I am now waiting for some glue to dry.

I will try to post a couple of more pics tomorrow evening, but it may not look a lot different from the last one, even though there are a few more hours in it.

I took Friday off, hopefully now that I'm building again I can make some good progress.

I got some motor connectors from EBay in the mail today. I'm not sure but I think the only major thing I don't have is a box/case to hold the electronics. Not sure what I'm going to do there yet. The first power on test is liable to find electronic assemblies and wires strewn everywhere.

BobL.

[boblon]

Spent the few hours I had tonight doing some work on the Z-Axis assembly.

I'm really hoping to put some power to it this weekend. Have a lot of work to do to get to that stage though.

I never really noticed it until now, but I now realize it seems one of the big difference between the Rockcliff plans and the others I looked at is the orientation of the motor on the Z-Axis assembly. With this design the motor takes itself for a ride, while on others the motor is stationary and the carriage that holds the router is the only piece that moves.

The Z-Axis seems to be getting heavier the more I build it and I hope these motors I got will move it.

Anyhow, here's a couple of pics of tonights progress on the Z assembly.

BobL.

[boblon]

Got the Z-Axis assembly done for now. I made a temporary clamp to fit a RotoZip. I don't plan on that being permanent but plan on using it to make a proper one for the tool I end up putting there, which is undecided at this point.

Screwed up one of the gantry sides and had to make another one. Glad I didn't pick a critical piece to mess up.

It is clamped up in a semi-aligned state. Have to figure out how I'm going to attach the Y crossbar assembly to the gantry sides.

Being as it's made out of MDF I'm wondering if I should try to build in some sort of fine adjustment for potential movement of the Y-crossbeam? The gantry sides are going to be bolted (not glued) to the sides, so I imagine that would provide the necessary adjustments.

I'm also wondering how much those with MDF machines find tuning the alignment over time necessary?

Also wondering if I should hook up the electronics before performing final adjustments?

But that's it for today.

BobL.

[boblon]

Well, I will be ready for the initial power up and testing tomorrow.

All I have to do is finish the preliminary alignment and lock her down.

As you can see in the pic my Y-axis lead screw could be a little longer. Got it before the linear slide. Oh well. I haven't secured the bearing block on the Y-Axis yet either (need some material).

It sure has been a learning experience up to this point. I can sure see why everybody seems to build the first one just to turn around and build a second one. Not only because of what you've learned as far as what your trying to accomplish, but so many things that you wish you would have done different.

But, be that as it may, what's done is ALMOST DONE !!

Now, if I can hook up the drivers withoug blowing them up I will (hopefully) see some motion out of this beast. Can't wait.

BobL.

[glenfraser]

HI Bob.
A couple of questions...

1) Were do the metal stepper coupler boxes come from ( the bit between the mdf and the stepper)

2) Were do the anti backlash nuts come from....


Thanks


Glen (UK)