3rd Generation Router Build

[yukonho]

I have been picking away at this project for nearly two years now, and it is finally close to completion.
This machine is a refined version of my current machine that has done me great service over the last year and a half. This machine is an enclosed torsion box design. It is incredibly rigid and the enclosure keeps dust and noise inside. You can stand beside the machine with it running and carry on a normal conversation, no hearing protection needed. My shop (originally in my dining room in my last apartment!) stays completely dust free.
The MDF came back from the CNC shop the other day, and it looks great. As you will see in the photos, all of the joints are dado'd for precise and solid fit. The windows and thrust bearings are flush, and there will be a front panel that will house the power supply, stepper drivers, a fan, power switches, and eventually a pendant control. I designed the machine to self align as it is built, guaranteeing a square machine.
I approached this design with the intent to make it a kit so anyone can assemble this machine without having to deal with the difficult parts of a DIY machine. This machine is the first one off the presses, and will likely need a couple of tweaks here and there.
I will be using IGUS slides for the X and Y (moving table design). And a V bearing type slide of my own design for the Z. I researched and experimented with the IGUS slides to be sure there will be no slop.
Here are some pictures of the parts.

[yukonho]

Here are a couple pictures of the table and gantry torsion boxes going together. These are a bit snug and took some tapping with a mallet to get them together, I will add .005" to the grooves to let these parts fit together a bit easier.
You can see the mounting holes for the IGUS slide carriages in the bottom of the table, and the grid of holes in the lid will have 1/4-20 T-nuts installed for fixturing.
All screw holes are countersunk.
You can see the alignment holes in the gantry torsion box bulkheads. I will be running 1/4-20 allthread right through the gantry with a washer and nut on each end to tie the machine sides and gantry together.
Colin

[vacpress]

I hate to say it, I am sorry, but do we really need another plans\kit for a simple MDF CNC machine? It seems absurd. I was searching ebay the other day and there are lots and lots of them allready out there... Please, design it real pretty. the only set of plans ive seen were real real ugly.

Keep up the good work!

[Jason Marsha]

Keep up the good work. Your compact machine with the enclosure feature would be great for those who need to keep dust and noise to a minimum.

Jason

[campaX]

I Like the design!. Keep posting.

[yukonho]

Thanks for the commens guys.
Vacpress, the very reason I had to design my own machine to suit my needs was because there is nothing out there that is worthwhile. All of the plans I have seen are one or more of the following; ugly, flimsy, poor design, difficult to make without a machine shop and extensive tools, no enclosure.
Another motivator for me was that I have yet to find a kit for a cnc router, period. I think I found one once, but it was a weak design. I figured that there are lots of guys who would build a kit that dont want to build from plans. I have designed the machine to go together with a few basic hand tools, and nothing else needed.
Here is a link to the build of the original. http://www.cnczone.com/forums/showthread.php?t=3059

colin

[buscht]

Colin, Congratulations on the baby!

I think that you might be on to something here with the kit. Any idea about a price point?

Good luck and don't let anything stop you.

[yukonho]

Thanks for the Congrats. Our daughter, Zoé, is 5 and a half months old now, and she is spectacular
As far as price point goes, I am close to having a final price, but need to finish up the Z axis and a few other things before I can commit to a price.
As far as not letting anything stop me, well it has been two years of picking away at this project when time and money were available, I am so close now I can taste it, I wont let anything get in the way!
Cheers,
Colin

[campaX]

I really like your design...
so I'm trying to make a clone, with a working area of 440x800mm ~(17.3" x 31.5").

What do you think?

[yukonho]

I think you will be fine enlarging the machine to that size. Build the torsion boxes nice and solid with 3/4" MDF and you will be fine with respect to rigidity.
You might want to follow through this build before you get going on yours, there are a few design features you may also want to incorporate into your machine.
Colin

[vacpress]

So, I looked at the thread and these pictures.. Not to bad, nicer than the terrible moving-gantry design out there... with the single piece of MDF on either side for the gantry vertical supports... 2 pieces seems so much more rational.. and NO MOVING GANTRY MADE OF MDF AND ALUMINUM ANGLE! Duh.

Keep it up.. Got the prototype built yet?

Happy holidays with the baby!

[yukonho]

There are a lot of aluminum machines that are as flimsy as the mdf moving gantry routers are. I spent a lot of time on this design to get the geometry right to make it uber rigid. I can stand on the table or gantry with no noticeable flex (I think I will put a dial guage on it and get a real measurement).
Haven't had time yet to do much more, but I will this coming week; I will be off work.
Colin