Heavy 2X4 Router

[gd.marsh]

Just finished a 2X4 router and thought I'd post some shots in case anyone might be interested in how I tackled it. This forum has been a gold mine of ideas and knowledge for me during this 6 month long project.

[FandZ]

Very nice. So nice and shiny I'd almost not want to cnc anything just to keep it looking clean. What kind of materials do you plan on machining. Or better yet, what type of materials do you think your machine couldn't do? Fantastic job on the wiring.

[gd.marsh]

It was actually built for routing hardwoods .. specifically custom guitars. But I was very interested in a solid machine to help with accuracy. All the best components won't help if the machine is flexing, vibrating & bouncing around while trying to do it's thing. I suppose it will mill aluminum, but I wouldn't really want to try too much of that with a router as a spindle. My problem is, I've worked with big woodworking machinery and have always been taught the quality of a machine is usually revealed in it's weight. I know that's only true to a certain point but thought I'd incorporate the concept into my design.

[LazyMan]

Nice Job!

What tools did you use to cut or machine your larger aluminum plates?

[gd.marsh]

I used a vertical band saw running slow with a coarse blade .. cut like a dream. Edges were then cleaned up on a mill/drill and the entire gantry polished after all holes were drilled & tapped for assembly.

[FandZ]

Originally Posted by gd.marsh It was actually built for routing hardwoods .. specifically custom guitars. But I was very interested in a solid machine to help with accuracy. All the best components won't help if the machine is flexing, vibrating & bouncing around while trying to do it's thing. I suppose it will mill aluminum, but I wouldn't really want to try too much of that with a router as a spindle. My problem is, I've worked with big woodworking machinery and have always been taught the quality of a machine is usually revealed in it's weight. I know that's only true to a certain point but thought I'd incorporate the concept into my design.

Stiffness is good but stiffness and weight is best. Before anything has a chance to flex, the router has to overcome the weight. That machine looks to grand for a router though. You should pony up for a spindle and a VFD.

Looking at all that polished aluminum makes me wonder if I can polish my 80/20 extrusions.

Nice job

[gd.marsh]

Actually, the plan was to start with the router and see how it goes with the understanding that a spindle my be following. Already have a sizable investment in the machine and figured beginning with a router would buy some time to save some $$ for a Spindle & VFD. I would guess you can polish just about any aluminum but it's no quick and easy process I can tell you that. Lots of work, real glad my son tackled that part of the project! The aluminum plate actually came from a scrap yard, so even though it's not perfect, it's a huge improvement in the overall appearance of the machine.

[ger21]

I was trying to figure out how (and why) you had two steppers connected together. Then I realized it was the reflection in the polished side.

[gd.marsh]

That picture can be puzzling at first glance .. can't it?

[Jason Marsha]

That's a very good job.

[gd.marsh]

Thanks for the kind words .. I found a couple more shots so thought I'd add them to the thread ..

[gd.marsh]

Finally came up with a dust shoe bracket to allow for some up & down adjustment. When I built the machine I purchased the K2 router bracket that was made for the model of Milwaukee router used. A word to the others considering this combination .. the hole in the brackets meant for the adjustment rod to hang your dust shoe on gets partially covered by the router itself, rendering it useless. It seems that K2 did not actually design this bracket for the Milwaukee router, but made some quick modifications to an existing bracket design. The pictures are what I came up with, will include more when I get it mounted on the machine.