New Machine Build- 49" x 97" MechMate Build in Houston Texas, USA (detailed log)

[dmoore]

For the legs I elected to use 2" x 2" x .120" wall tubing since I feel it looks a little more finished and I didn't mind purchasing another type of steel. More importantly, it allows me to use these nifty little nylon inserts from McMaster-Carr (60945K31) and these really nice self leveling feet (6111K373) also from McMaster-Carr.

For the bracing, I am using 2" OD x .083" wall tubing. For the tube on tube action I am fish mouthing the joints using paper templates.

To crush the ends where the tube meets the beam and legs, I used my shop vice. Does anyone have suggestions on a better way to form the crushed/oval ends?

Even though the cross bearers are bolted, I will be welding the side supports back on after I paint it. The tinking is - if I need to disassemble it in the future, I can just cut off the side supports, move it and then re-weld it upon reassembly. The main beams with the legs and supports is liftable my one person, so with the boltable cross bearers, it makes the MechMate "somewhat" portable.

[dmoore]

I finished the legs and support structure, so now it's time to flip it over and reassemble it. I propped up one main beam with my workbench and then with the two end cross bearers attached to the other beam, I lifted it upright and then attached it to the other beam. Once both were attached, I "walked" it crab-style into position where I squared it up and then attached all the remaining cross bearers. All done it was within 1/4" square.

[dmoore]

Other than some confusion about the pictures for the weld-up being for the orginal MechMate and which side the the counter sunk holes go on, it all snapped together perfectly. Here here Gerald!

I know that Gerald says that clamps aren't neccessary but rather than risk it and to close a few small gaps, I put a few clamps on it.

When it was all said and done, it turned out completely true and straight.

[dmoore]

I'm sorry I didn't finish my posts but I have completed my MechMate. In the process, I have posted a very detailed BOM for the MechMate here:

http://www.mechmate.com/forums/showthread.php?t=814

Link to the current MechMate BOM in Microsoft Excel (2003 format):
http://www.dmoore.com/MechMate/bom.xls

Link to the current MechMate BOM in HTML format:
http://www.dmoore.com/MechMate/bom.mht

[lumberjack_jeff]

You've done a huge amount of work documenting the requirements. Thanks and well done!

When I'm ready to build, I need to look carefully at your solution.

[harryn]

Hi, Thanks for posting this - nice work.. Did you happen to post any final pictures of the unit or video anywhere ?

[dmoore]

Originally Posted by harryn Hi, Thanks for posting this - nice work.. Did you happen to post any final pictures of the unit or video anywhere ?

I don't have any photos of the completed, painted MechMate posted yet but I do have video of it prior. They are posted here:

Introducing the "full-size" MechMate router