Porter Cable 9690LR

[Drools]

I'm looking for some dxf files for a mount. I know K2 sells a mount but I think I will take a crack at making one myself. If I can make a mount, I can spend my cash on some collets for it. There is no way in he... that I can make collets but I just might be able to make a mount. I have access to 1/2" UHMW plastic and of course MDF. I might even have some 1" UHMW or be able to get some.

[Thazul]

You could probably use the drawings from Joes 2006 R2, but I think you have to make the hole a little larger.
The one for the router used in Joe's has a 3 5/16" DIA, I believe your router is 3 1/2" DiA?
Here's a link http://geno.boxgods.com/Joes_CNC_Model_2006_R-2.zip

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Andy

[Drools]

Thanks Andy, I did see the Joe's mount yesterday and it looks quite good. I was also looking for other ideas. Yes I think the diameter is 3.5".
I have seen 3/4" mdf used but is it really strong enough?

[Thazul]

I have not used MDF personally, the first mounts I made were out of 3/4" hardwood planks, then with those mounts I later cut 1" aluminum ones.
I think a lot of people use those HDPE cutting boards.

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Andy

[bill south]

I don't know if these will help. I cut them in aluminum and used them with my Porta Cable with a 3.5" body. Hope they help.
Bill

[Drools]

Thank you very much Bill, I will give your design a shot. I told a friend what I was building and he suggested making it out of Trex, the decking plastic. He says it is cut with normal hand/power tools so a normal endmill should cut it without melting. Has anyone used this type of plastic to machine with?


Edit:
I found this thread which answers my question
Have you ever machined Trex Decking?
"machines like butter" was the phrase which I was looking for.

[Drools]

Trex, update.
I purchased a 12 foot by 1"x6" piece of this stuff http://www.trex.com/accents/ in Saddle. It was on sale for 20.00CAD.
The actual size is 5.5"x1.2" with the simulated grain side being slightly crowned. I guess this is to allow water to drain off the boards. The edges are slightly rounded so I would estimate working piece with 90degree corners would be 5"x1". I cut a small piece off the end and routed off .04 from the grain side, I'm using my spindle which is designed to route PCBs but I had no problem surfacing the Trex. It went very smoothly without any melting or rough edges. The bit I used was a simple 2 flute endmill with 1/8 shaft. You can see the bits of wood in the plastic but the feel is very smooth and hard, I cannot scratch the surface with my finger nail. I'm going to make my Porter Cable mount from this stuff.

[FandZ]

I think I've seen some of that TREX stuff before. I was thinking about a build useing some 4x4 beams out of it. If it's the same stuff, it's heavy and solid as can be. How's the stiffness of the planks you got? It could be a cheap alternative to getting plastic stock for small parts.

[Drools]

I made my router mounts out of Trex, here are some pictures.
Even though the Wolfgang spindle is underpowered it cut through the Trex no problem. I made 2 pieces each are 1" thick, I want to glue them together however all of my glue tests were unsuccessful with the glue I had. I was told to try Gorilla Glue and I have to say it is good stuff when used properly.

[FandZ]

How was the dust when you machine them? Any floating particles?

[Drools]

no nothing floating in the air.

[FandZ]

Sold... I'll go pick up a plank of it tomorrow. Since gorilla glue expands, scoring the surfaces wold probably give the best bond. Hopefully my results will come out as good as yours did.