New Machine Build- Finally Finished It. New Aluminum/Steel Router

[bill south]

Several months ago, the boss let me know that we needed (had to have) the kitchen remodeled including new counter tops and cabinets. Well, I priced the cabinets and wow, was I surprised with the cost. So, I built this little machine to make cabinet doors and will re-use the old boxes with a new finish.
To date, I have not cut any new doors but my test cuts have made very nice signs. However, now the fun is over and time to get to work on the kitchen. Well, at least I got a new toy out of the deal.

Enjoy.
Specifications

Construction Material, Steel, Aluminum and a small amount of MDF.
Cutting Area - About 32" X 36"
Servo Controllers - UHU Drives - (hell yeah they work)
Servo Motors - NEMA 34 (way over sized but had them in stock)
Mach 3
Vacuum Table (4 quadrants - low density MDF) (shop vac)
Dust Collector - Harbor Freight (yeah, I know)
Ball Screws all three Axis.
All machining done in house (well in the shop)
Just a fun machine.

[bill south]

Here are some Pix - I hope.
Bill

[gd.marsh]

Nice machine Bill & Great dust shoe! .. were all parts manual machined, or is one of the mills in the background cnc? I'm thinking real seriously about converting my mill/drill to cnc and finding another smaller knee mill for the manual stuff.

[yantra3d]

Excellent build you got there! If I could I would build one just like that... looks to be an excellent design, etc...

Any idea of how much you have invested? (if you don't mind me asking) How about man-hours, did you happen to keep track at all?

Great work!!

[stevespo]

That's a great looking machine, and I'm sure it will perform equally well. Very nice design, with the servos, ball screws and the steel rails/bearings.

How is the vacuum table working out? Had a chance to put it through it's paces yet?

Steve

[bill south]

Thanks Guys;
All parts were made on my Lathemaster Zay CNC benchtop. I did use the manual mill for simple jobs but for the most part, it was the lathemaster. I don't think I would have tackled this project without some CNC assistance. As for the design, I saw a picture of a similar router here on the zone and drew up my interpreation of each part using BoBCad (ver 21). Bobcad generated the gcode and the part was cut using the Lathmaster. Jigging some of the larger parts took some imagination due to the mill enclosure, but heck, that was part of the fun!!!!
Regarding the cost of material and time consumed with the project, heck, more than I expected to spend and worked spare time for most of the summer. As is mentioned earlier, I was winging the design so many tasks were performed multiple times. But again, that was part of the fun!!! Toward the end of the design, I was getting better with Bobcad (now ver 23) so I was able to test fit the parts in cad and check for clearance/interference, all prior to cutting them on the machine!
The vacuum table works great with the parts I've tested. Only one problem so far! I was cutting a memorial plaque for a buddy of mine and the work was going fantastic. Using a 20 X 29 MDF 3/4 blank (Lowes), I was running a 1/2" v-cutter at 100" a minute and the thing was really honking along. All of a sudden, I noticed the sign was moving a slight bit with each move of the router and my design was turning to crap.
Turns out that the 110V plug from the vacuum source (shop vac) had vibrated out of the recptical which was mounted on the machine itself.
One thing about this rigid design, it does tend to dance a bit when making 100" rapids and cuts. Anyway, the first cut was screwed but I've learned a lesson! Secure all the plugs!!!!!! I didn't hear the shop vac stop because of all the noise of the router and the dust collector.
I'll try again this weekend though. This thing is a blast to watch. I kind of wish I had used steppers just to hear it moan and groan during axis movements (lol - not really)
Thanks again guys for looking.
Bill