New Machine Build- CNCDemon Barracuda 3-Axis Router Build

[HippoDan]

It has begun.

I am finally getting a chance to build a machine where I have a hope of having enough time to document the build properly. I'm taking a bunch of photographs, but more importantly I'm trying to videotape every step of the way. This build will hopefully constitute the instruction DVD that will go wtih the kit.

And, I haven't glued anything in backwards so far!

Let me start off with a few pics of the Barracuda parts still on the table of the larger CNC that cut them. The endless landscape of cut parts is always cool looking.



For the kit, all the pieces are labeled and numbered, so that you can tell which goes with which assembly. This actually kind of matters since the X-Carriages are mirror images of each other.

And, here they all are popped out and ready to go.


The rails for the X-Axis are over 5ft long. I didn't want to join the long axis in the middle, it makes it too hard to keep everything straight. SO, it needs a bigger box to ship. No big deal.

Some steps are missing photos, but every step has video, it may take me a little while to get the video uploaded, but I'm working on it.

For those of you that dont' know what the finished item will look like, I'll let it be a surprise...
But some of the specs are:

3-Axis Router
25 x 49 x 7 Travel (Actually 27.5 x 51.5 if you hit the stops)
Belt Drive (2 tpi equivalent)
HobbyCNC 305oz/in motors (At least that's what I put in it)
Jog speed in excess of 600 ipm!
Hitachi 2.25 HP Router (Again, that what I picked)

I'll take it a step at a time. I think I'll start with the X-Carriages, and work from there. Most of my build order has been determined by which items I need to get into the paint booth first. (And by paint booth, I mean folding table with paper and tape folded up on itself. You'll see...)

I'll get crackin' on that video.
-Dan

[Hirudin]

I haven't read anything yet, but that looks awesome!

OK, read your post now...
It looks like you have a good plan. The scale is hard to determine, is that 3/4" MDF?

[SatanKlawz]

Is this a kit that you are going to mass produce and sell?

[HippoDan]

Hi, Most of it is 1/2" MDF to save weight, with the important bits in 3/4"

It is a kit, and I hope to sell a few. A lot of my friends were loving my big CNC, and kept asking me to make a smaller one that they could do at home. I figured that if they wanted it that badly, a few other folks might as well. And I get to design a 4th Axis which is something I never had on the big one.

A lot of the guys I talk to are model airplane guys, and they're happy to glue parts together, but don't want to do much cutting. I'll cut and drill the steel and count all the nuts and bolts to make it easy.

-Dan

[BobF]

Post some pictures of your "big CNC". We would love to see 'em.

[HippoDan]

BobF,

Sure thing. I'll take some pics at some point. My big machine is mostly Shopbot, and I'm very happy with it, but I spent $$$ getting it the way I want, and cut airplane kits, molds for vacuum forming, and do some paid prototype work with it. Hobby level seems more about getting the most bang for your buck if you're willing to work for it.
In the meantime the table is all covered in tools and dust and miscellaneous junk, so it may be a while, but you can see pics of it in the background of many of my photos and videos. I built a lot of the Barracuda right on it, since that table seems to be the only flat level place in my entire house.

Anyway, after being spoiled by the big toy, I definitely wanted some big specs on the this one. Had to have 2'x4' minimum. Had to have at least 2.5in/sec (150in/min) cutting speed for the foam I cut. The faster the jog speed the better.

I've got some pics of one of the X-Carriage assemblies. I'll type something up.

-Dan

[HippoDan]

I've got some pics here of the X-Carriage build. The video is still in the camera, and I'll see about getting it off of there. I'm a bit ahead of things, and I'm still trying to video the nuts and bolts part of the assembly. It's hard to make time to stop and edit video when I'm so close to being done.

Here's the batch of X-Carriage parts laid out on the table:


I made a cool thing that holds a Sharpie marker in the router collet and labeled all the parts. It's spring loaded for uneven surfaces and you can change out the marker in a couple seconds. Cheap and easy to make. I'll post some instructions on how I made it in the CNCDemon.com forums at some point. Just remember: Don't turn on the router with the marker in it!


X-Carriage parts 1,2,3 go together first. They're where the Y-Axis will mount.


Part 4 is a bearing support for my secret weapon against racking!


That assembly fits into one side panel


The large piece is 3/4" MDF. The bearings and drive pulleys will mount in some of those holes


Parts 6 and 7 reinforce against any twist


The second panel goes on and one X-Carriage is done. The other is a mirror image. Those elongated holes near the bottom are part of my secret weapon against having to by eccentric bushings!


I got too caught up in building and shooting video to take too many pics of the other carriages while I put them together, so if I can't get to the video, I'll post the pics of the X-
Axis torsion box build, and lots of cool pics I took while watching paint dry.

More soon,
-Dan

P.S. I just noticed, but looking at all those cuts in the spoilboard below really looks like some alien planet or something. Almost make me feel sorry I'm going to have to surface it flat again soon.

[HippoDan]

I just got back from the SEFF (Southeastern Electric Flight Festival) show in Georgia. It was a blast. I had the machine up and running and tried to make as many parts as I could for various folks.

I think I am now hating the Hitachi router. The 1/2" collet feels like a cheap piece of junk. My Makita router kept failing, so I bought this brand new Hitachi before heading down there. It ended up having so much runout that I couldn't cut anything accurately. My 3" tool holder with 1/32" endmill had more runout than the bit diameter! Needless to say the bits kept breaking off.

Does anybody have suggestions for a 2-1/4 range horsepower router? I'm looking at the Craftsman. I may go pick one up this afternoon and see how it compares. Amazon is sending UPS to pick up the Hitachi and take it away today.

I've got photos and video from the show, I'll get some off the camera today.
-Dan

[nlancaster]

Originally Posted by HippoDan P.S. I just noticed, but looking at all those cuts in the spoilboard below really looks like some alien planet or something. Almost make me feel sorry I'm going to have to surface it flat again soon.

Pull it off paint it and sell it as "Modern art"!!!

those parts look very clean, can't wait to see what your machine looks like.

[cdndave]

Originally Posted by nlancaster can't wait to see what your machine looks like.

Ditto - my first build's purpose is to build a fancy 2nd machine Your machine is beautiful (at least it's piece's are)

Dave

[BobF]

Originally Posted by HippoDan I just got back from the SEFF (Southeastern Electric Flight Festival) show in Georgia. It was a blast. I had the machine up and running and tried to make as many parts as I could for various folks. I think I am now hating the Hitachi router. The 1/2" collet feels like a cheap piece of junk. My Makita router kept failing, so I bought this brand new Hitachi before heading down there. It ended up having so much runout that I couldn't cut anything accurately. My 3" tool holder with 1/32" endmill had more runout than the bit diameter! Needless to say the bits kept breaking off. Does anybody have suggestions for a 2-1/4 range horsepower router? I'm looking at the Craftsman. I may go pick one up this afternoon and see how it compares. Amazon is sending UPS to pick up the Hitachi and take it away today. I've got photos and video from the show, I'll get some off the camera today. -Dan

Dan,
Get the Milwaukee 5625 3 1/2 hp variable speed router. The 1/2" collet has near 0 runout, and the 1/2 shank ER16 collet I have shows near 0 as well. I use it for 1/8" shank bits to cut pearl. larest bit is 0.0625 and they go down from there. Runout in the combination is not measureable with the dial indicator I have (.001)
Lots of power and no runout. I love it.
This site has great deals from time to time.
http://www.heavydutytools.net/Scripts/default.asp

[New2CNCPaul]

Originally Posted by HippoDan I just got back from the SEFF (Southeastern Electric Flight Festival) show in Georgia. It was a blast. I had the machine up and running and tried to make as many parts as I could for various folks. I think I am now hating the Hitachi router. The 1/2" collet feels like a cheap piece of junk. My Makita router kept failing, so I bought this brand new Hitachi before heading down there. It ended up having so much runout that I couldn't cut anything accurately. My 3" tool holder with 1/32" endmill had more runout than the bit diameter! Needless to say the bits kept breaking off. Does anybody have suggestions for a 2-1/4 range horsepower router? I'm looking at the Craftsman. I may go pick one up this afternoon and see how it compares. Amazon is sending UPS to pick up the Hitachi and take it away today. I've got photos and video from the show, I'll get some off the camera today. -Dan

Dan the Hitachi is a great router, but their collets are not! Look in to getting some Precision Collets and nuts. I use a set from PreciseBits.com

http://www.precisebits.com/products/...h_1618_Collets

You also need to remember that the further you get away from the collet the worse the runout will be, Tool holders are not really meant to be used on Routers.
Paul