Build Thread- 8020 ErectorSet Router...

[Senna]

Construction began on my 8020 machine over the weekend. I've been slowly gathering the components for the last several months and the final shipment of aluminum landed on my doorstep last Thursday. Whoo-hoo! I've noticed several nice 8020 machines have been built recently so I hope my build falls into that group once completed.

It's a conventional moving gantry design using THK & Hiwin linear slides and bearings on all three axis. Toss in some of Ahren's (www.cncrouterparts.com) bearing blocks, Dumpster's (www.dumpstercnc.com) AB nuts, clamps and couplings, a sweet 370mm THK ballscrew (eBay), some 5 start 1/2-10 ACME leadscrews (McMaster-Carr), Gecko 251 (www.geckodrive.com/) controllers, etc... etc... and I should end up with a nice compact CNC router having a cutting area of approx. 20" X 28".

Using my DeWalt 12" miter saw I managed rather easily to make all the necessary cuts from the stockpiled 8020 sections. LOTS of hot flying chips... but at least they are, for the most part, moving away from you! Make certain you securely clamp the stock being cut... and ALWAYS wear eye and hearing protection. It took less than an hour to cut all the pieces.

I'm currently awaiting an order from BoltDepot but went as far as I could with the assembly using 8020 hardware on hand.

I've attached a couple drawings and pics... more to follow...

Senna

[Senna]

The UPS Tracking says my BoltDepot order is OUT FOR DELIVERY! So... I should be able to make a bit more progress this coming weekend.

Prior to turning in last night I was able to test fit the majority of the components for the table base. The assortment of plates used was due to winning an auction bid from the 8020 Garage. It was a hodge podge assortment of 15 series plates. These will function exactly the same as the higher priced spread... and I'm all for saving money where I can.

More will follow as it happens...

Senna

[Senna]

It will require M5 and M3 SHCS to secure the Hiwin and THK rails to the 1530 series 8020 extrusions. Some of the more typical hardware used with 8020 is their economy T-nuts. Since the size I require is not offered I made the decision to create my own. It's very straight forward. A simple matter of a few cut fender washers, hex nuts, and a bit of tack welding. Split lock washers will be located under the head of the SHCS in the rail itself. We will see if this arrangement maintains a tight screw or requires frequent attention.

[JerkyBoy]

Check this out

http://tinyurl.com/3oyf3b

JerkyBoy

[JerkyBoy]

www.bwc.com

12421022

[JerkyBoy]

http://tinyurl.com/4446ng

[crocky]

I would use the last one and exactly as shown in the diagram, the curve makes the nut sit in exactly the centre of the 8020 and it means that your rails will be centred.

Thats what I have used and it is very straight!

Bobs Aussie ITEM Router Table Build

[Senna]

I'm still working out the details with the manufacturing of the homebrew t-nuts so I began bolting some sections of the gantry together. As an economy move I'm using 5/16" X 3/4" carriage bolts for the majority of the hardware... however I did run into an unforeseen issue with clearance when you have a vertical and horizontal bolt in all 90 degree bracket corners. There just is not sufficient room for the carriage bolt and hex nuts on both axis. This was solved easily enough with 5/16" X 3/4" button headed cap screws and economy t-nuts. I happened to have some on hand left over from the table frame build but I will need to throw a bit more money toward the 8020 Garage guys to get the number I need to complete the build.

I've attached a couple of closeup pics showing the bolt issue solution and a pic of the gantry partial assembly.

Senna

[High Seas]

Don't pitch your carriage bolts! You can use them as hold downs in you t-slot table if you go that way!
Jim

[Senna]

With the completion of the homebrew T-nuts for the rails on all axis... I began rail attachment for the gantry and table frame. I then moved on to completing the component assembly for the gantry. At times it requires five hands and a small boy to line up the hardware... but I somehow managed it alone with only a modicum of Navy talkin'! The sequence of assembly requires careful planning as there are areas where the hardware is captured and can't be installed after the fact. It certainly requires thinking in three dimensions...!

It does assemble rather quickly when all goes well... and you are not retracing your steps.

Next up is the interface attachment for the bearing trucks and 8020 skates that will ride atop the X-rails.

Senna

[Senna]

Today I fit the gantry onto the table base. This was to check the X-axis rail alignment. Those that have gone before me will know when I say the experience of seeing and especially feeling the axis movement is truly satisfying! The movement is so smooth and has a buttery fluid feel for lack of a better description. Hard to explain... but a delight to the senses!

Senna

[CRFultz]

Nice work Senna, Looks like a solid machine.

Chuck