FesTool Router I used in my latest build

[msimpson99]

I plan on putting up complete free step by step instructions to build this on one of my web sites.

[DonFrambach]

Looks great! Have you measured the Festool's runout? Could you show a photo of the mount you made to attach the Festool router to your Z axis?

[brtech]

Looks real nice. Festool makes very nice power tools. Was there a particular characteristic you liked in this application? It's a VERY pricey item.

What is the "e-chain" made of? Looks like some kind of plastic web with bars holding the wires down. Seems to work very well.

I like the cooling fans on the motors. Do you have any evidence they actually help anything?

[msimpson99]

I own 8 routers. The festool routers have the least runout of anyof them. As for the Festool mount that will be described when I write up the instructions.

I was using a Bosch Colt but it had issues.

1. not electricly conductive so it was a pain to use probes
2. lots of runout

The Festool has about the same rateings on paper but blows the colt away in performance. I used it on my last build.

The motor controller kit I used is very powerfull but the motors warm up and the temp will get over 300deg if it sits idle for very long. Even with the g540 going into idle mode.

I did a lot of research with the echain. The first was done with aluminum flashing with holes drilled and tiewraps holding the wires. It worked but was hard to manage the cables. This one uses flexable vinal with some little bars I cut out of hardboard with my laser. Its so simple I dont know why I didnt think of it before. Very easy to add or remove a cable.



With the fans running no motor gets over 90 degrees. So my answer is yes Fans rule. My only other choice would be to lower the voltage which would reduce my power.

[brtech]

Festool makes a superior product, no doubt about it. What kind of runout are you measuring and what was the Bosch? Are the collets as good as the precisebit collets you can get for the Bosch?

re: echain. I like it even more. Where did you get the vinyl and what holds the hardboard to it?

I'm gonna have to measure my motor temp. I know they get very hot to the touch when they are just holding position.

[msimpson99]

On the router I get less than .001. On the bosch its .005 to .01. Im sure a new collet would help but the Bosch has other isues that just wont work for me. I cant use a probe unless I attache lead to the bit. Also the mounting of the Festool is perfect as a spindle as it has its own mounting bracket.


When the Festool once mounted has two posts that let me attach a dust shield and vacume. Last but not least the Festool runs much quieter than the bosch. No vibration and more range on the speed.

The design on this build will support larger routers but the table size is just too small to warrent it.

[msimpson99]

Here is the probe I built. The Festool is conductive so I only need a single wire and dont have to camp anything to the bit.

[msimpson99]

Got the hold down system just about perfected. This is a small gear cut out of 1/4" Popular at 100IPM.



The Gear



Just had to clean the small tabs I left in place.

[msimpson99]

Just wanted to see if I could cut some holes in aluminum. Its a 1/4 straight bit. Not the best for this, but quick small passes at about 10000 RPM worked pretty good.




The result

[kolias]

Nice machine msimpson99, will be interesting to see the details

[msimpson99]

In answere to a previous question about the Festool router. If you set it to 10000 RPM the routers internal electronics has a feedback system. It will do everything to maintain those RPMS. Its very powerfull at the low RPM speeds unlick the colt or other trim routers.

This router has performed so well that Its sloted for my next build.

[msimpson99]

Thanks Kolias. We are going to start a new build for this design next week. I have two individuals lined up that will be doing the build in the shop so that it can be filmed and photographed for the web site.

Im debating which site to post it on. I could restructure my www.kronosrobotics.com site or my Welcome to Kronos Robotics site. Or I could just start a whole new one deticated to cnc.