Need some basic design and build input

[Dman65]

I am wanting to build two CNC routers. One would be a small router somewhere in the 12"x12" range which would be used mainly for HDPE and aluminum. In addition to using it for making parts for other hobbies, I want to use it to make some bearing and motor mounts for a larger router in the 48"x48" range for wood to make parts for cabinets and other furniture.

Right now I am struggling with how to build the 12"x12" machine. I purchased plans for a 10"x9" machine from Solsylva.com and while the plans look to be very straight forward and easy to follow, I have doubts about a router made from 1x4 and 1x6 wood being able to reliably cut aluminum and stay in tune.

I am wondering if anyone knows of a tried and true design in this size.

I looked through the FAQ questions, but I really couldn't find much about designs and the best materials to use.

Would taking four 2"x2" aluminum square tubes and cutting the ends at 45 degree angles and then filling the resulting square tube with fiberglass resin mixed with sand or granite supply a suitable base for a 12x12 machine with a stationary gantry? If so, does anyone know how to go about squaring such a structure?

About two years ago I began trying to build a router approximately 24"x36" out of MDF and with cutting the MDF on my table saw and miter saw I just never got it square and level enough to even bother installing the screws and rails.

[mactec54]

Dman65

Take a look at my build here, You may get some idea's, of what is needed for a good solid build machine, Filling aluminum tubes would work for a base, but were you go from there has to be built just as well

http://www.cnczone.com/forums/cnc_wo...ld_friend.html

[RomanLini]

Dman, check out my small router build;
http://www.cnczone.com/forums/cnc_wo...ll_router.html

It basically uses 2 large pieces; an aluminium base plate, and an aluminium "L shaped" gantry (both 10mm plate). These 2 pieces bolt together with a couple of small right angle pieces that can be anything including box section.

It's a good design choice for 12"x12" router and if you bolt a few more aluminium square tubes under the base plate etc it's very rigid.

For the 2 large pieces you can contract that out to somewhere local that will cut them square and to size, many sign shops have routers that can cut 10mm aluminium for a reasonable price and the shapes are very simple (ie cheap cutting).

You can even cut it on a decent table saw, some aluminium suppliers will cut plate to size for you on their table saw (which is pretty square too).

[Dman65]

Thanks for the response mactec54. Unfortunately, about the only tools I have access to are a cheap Harbor Freight drill press, a table saw, a router, and a 10" sliding miter saw. But that is a fantastic looking machine you put together.

Thanks for the link Roman. I will have to check around and see if I can find somewhere locally who can true up some aluminum stock for me. That might be the way to go. Nice looking machine by the way.

[ger21]

Rather than building a small machine, you may be better off buying a mill, and using that for your aluminum and plastic work. Especially if you don't have the tools to build something.

[louieatienza]

Originally Posted by Dman65 I am wanting to build two CNC routers. One would be a small router somewhere in the 12"x12" range which would be used mainly for HDPE and aluminum. In addition to using it for making parts for other hobbies, I want to use it to make some bearing and motor mounts for a larger router in the 48"x48" range for wood to make parts for cabinets and other furniture. Right now I am struggling with how to build the 12"x12" machine. I purchased plans for a 10"x9" machine from Solsylva.com and while the plans look to be very straight forward and easy to follow, I have doubts about a router made from 1x4 and 1x6 wood being able to reliably cut aluminum and stay in tune. I am wondering if anyone knows of a tried and true design in this size. I looked through the FAQ questions, but I really couldn't find much about designs and the best materials to use. Would taking four 2"x2" aluminum square tubes and cutting the ends at 45 degree angles and then filling the resulting square tube with fiberglass resin mixed with sand or granite supply a suitable base for a 12x12 machine with a stationary gantry? If so, does anyone know how to go about squaring such a structure? About two years ago I began trying to build a router approximately 24"x36" out of MDF and with cutting the MDF on my table saw and miter saw I just never got it square and level enough to even bother installing the screws and rails.

I have not made the small machine, but I did build the 25 x 37 machine, which is actually featured at the bottom most part of solsylva's gallery page. I had been able to cut some aluminum with mine though it's not the ideal. In his designs David Steele allows for some "slop" so that you can adjust for accuracy. Heck, I believe even he mentions that he uses the machine to prototype aluminum parts! If wood is the concern, you could substitute heavier material for almost all the components since it's a simple design - aluminum, or even phenolic. I'd probably get ACME screws however, instead of using allthread... But to echo Gerry's comments, you could buy a TAIG cnc-ready mill, and you'd have something far better than you could make with basic hand tools, but of course it's not as fun!