My first build Steel & Ali

[Action-KAT]

So I have been hovering on this forum for a while now trying to gain as much info as possible to build one of these wonderful toys !
well that's what I call it when I have no work for one.

I have very little funds to build but I will not be stopped, the build may take some time to complete as I'm short on funds being on 4 days for over a year now..

So anyway attached hopefully is a PDF file showing my layout design, this does keep changing as I go alone but that's how I work..

I have started building and will upload some pics of the build so far.

The cut area should be about 1050mm x 800mm x 150mm or there abouts.
Going to be cutting mainly wood in 3D hopefully and maybe some Ali.
KAT

[Action-KAT]

So here are some shots of the welding of the frame,
All has been a learning curve, first bit of welding not the neatest but does the job.
Main Steel frame is made of 2" x 1" with a few 1" x 1" supports sitting on heavy duty casters

I made the top part of the frame removable so i can pull it apart & pass it through a standard doorway if I need to, you never know.

I am trying to keep the cost as low as possible but make a solid good size router I can.

[Action-KAT]

So here are a few more shots.
The main frame took a weekend to do the bulk & finished off the following weekend.

Next Painted into primer then top coat, still needs a final coat when I'm finished messing about..

Tapped main 20mm rails to sides & bolted on.
Not sure the best way to line them horizontally to each other but seems ok.
We see how when I start mounting the gantry.
KAT

[Action-KAT]

So the next step for me was the hardest so far.
I brought a section of Ali plate 500mm x 500mm x 16mm thick.
When it arrived I think I went overboard with the size.
This is for the main sides of the gantry.
If I find it to heavy I will cut some sections out in the centre to make it lighter but still keeping the strength..
Anyway catch 22 not having a router to cut the ali plate means cutting by hand.
Had I thought a little in advance I could of made the sides out of MDF to start with then when I had it all working I cold of replaced them but cut them with the router.

Oh well I was to impatient to get things moving alone.
Out came the Jigsaw and a metal blade.
This was a long job little by little.
And when cut a lot of filing and sanding to make half decent

[Action-KAT]

So nearly up to date.
here are the latest pics been working on the gantry, again not to sure how to get the gantry sides and base and back all lined up, so just took a flyer.
First I drilled the side plates for the rail sliders, matched this on both side plates.
Bolted them to the carriages & checked they slide ok.
Next I used two clamps one top one bottom, tightened them little by little & kept measuring them until they had the same gap between them.
Now I figured that was the size to cut the next parts.
I scrounged a couple of bits of Ali sections
Base 150mm x 25mm
Top rails 75mm x 25mm
These where hollow so I had to fill them with some of the 16mm Ali off cuts from the side plates.
That worked ok I think.
So I pre drilled the sides & offered up the newly cut Ali sections.
Bolted them loosely then tightened them little by little while sliding the gantry up & down to check It wasn’t fouling up.
Again not too sure if this was the best way but seems to work, the gantry slides very smoothly very impressed with myself so far.
KAT

[beamsjr]

Very nice! I cant wait to see it finished. what type of aluminum did you use? 5052?

[Zygoat]

looks good. keep the pics coming!

[Jesse B]

Looks excellent so far! Moar pics

[Action-KAT]

Hi Beamsjr the Alloy was 6082T6, It wasn't to bad to cut with a Jigsaw just slow going kept spraying a little WD40 as I went alone,
would have cut lovely on a router if I had one handy LOL

[LazyMan]

Looking good!

That is a real nice job on the aluminum plates with that jig saw.

[DIYaholic]

Action-KAT,
Considering the size of your machine, I think the casters (even locking ones) will allow your machine to dance around a lot. You may want to find a way to secure your machine to the floor (or perhaps the wall). Just something to think about.

BTW, looks good from where I'm at. Good luck with the rest of your build.

Randy,

[Action-KAT]

Here's a few more pics after a couple of hours put in after work.
getting the rails on & a quick test of the ballscrew.

I clamped the supports for one of the ballscrews to the frame & clamped the ballnut to the cross member so I could check to see if it moved.
attached my cordless drill to the motor end and gave it a spin.
It's alomost live lol

I have a mov on my camera of it i'll try to upload it..

DIYaholic you are spot on the casters I was given so thought why waste them & as the frame is all steel & thework area is very small would mean moving the frame around alot..
I am going to put some form of stops on the bottom of the frame later so I can level the base up lifting it off the casters slightly.
Not sure how yet I was thinking alone the lines of how speed clamps work being a spring & rachat action..