Diary of a FoamCutter building a jgro router table

[voltsandbolts]

Glidergider,

The first cuts look good! I have looked at the Rockler T rails but have really tried to build my machine on the cheap. I am thinking of a grid pattern, maybe 4”x4” of holes for ¼-20 T nuts.

[Glidergider]

V&B
I hear you about the cost. 4 rails at $10 each, add Tee bolts and handles at $10, and it starts to add up to real money after while. I don't even want to think about my costs. Add software and whew.

Slots are important for ease of assembling your cutting project. In my case, I used the extra foot of Tee rail as a clamp. I drilled two holes for the tee bolt. I was wishing those holes were slots. Look at my clamping picture for clarity.

I've heard of some guys building their t-rails from wood. That might work too.

Regarding your grid, do it, but you will need slots in clamp bar for sure.

Dave

[Glidergider]

We are going to see our grand nephew tomorrow. He's a baby, but I thought I'd make little Luke a wooden plaque with his name in it. Here is my attempt. My router is still pretty loose, but I'm improving slowly.

Today, on a failed first attempt, the limit switch inadvertently broke. The cutting stopped of course. I'm using Mach3. When I tried to restart the project, it lost its position and ruined that effort. I started again with all the limit switches disabled. I'm pretty sure that after I gain more experience with this software, I'll be able to recover from such a stoppage without ruining the part.

Dave

[Glidergider]

Did I mention that I purchased a Hitachi router? Well, that means I need new motor mounts. So I just routed a new set of structural supports, using the old loud Craftsman router. Here are the details shown in pictures.

There are two different types of plastic shown and two different thickness.

The HDPE machines best and I bought it at .75 in. thick.

The thinner material is a scrap of Kitchen cutting board plastic. Awful to machine and it's really too thin. When machining it leaves lots of melted hairs. Finished edges require lots of deburring.
Dave

[tajord]

you can let me know how well that router works for you, i heard a lot of good reports on it, and pretty good for the cost, i'm supposed to get one on Monday, my PC router needs an amatuer, and i can't seem to locate one as yet, it's a really nice router, just not as heavy duty as i thought for the purpose i used it for.

[Glidergider]

Jordan,
I'm currently using a Craftsman 1.5 hp router. So far its plenty strong enough. The Craftsman is loud and its single speed.

The Hitachi is 2.25hp and quieter. The variable speed is an unknown commodity to me, but I'm thinking I'll like it.

Here's a picture of the motor mount after removal from the tabs. Perfect fit.
Dave

[tajord]

I suspect the extra .75 hp should help if you're cutting hardwood, what's the hardest wood you've cut so far with your machine and how did it perform?

[Glidergider]

I agree, the extra hp will help. Particularly when I slow the motor down. That's when the least hp is deliver to the cutter. So having more up front will help there.

The hardest wood I've cut is white oak. The plaque for Luke shown above. I took small 1/8 in. deep cuts. 1/4in dia up-cut bit.

[tajord]

The hardest wood I've cut is white oak. The plaque for Luke shown above. I took small 1/8 in. deep cuts. 1/4in dia up-cut bit.

Thanks, i'm just trying to get an idea on how it'll go cause i want to use it for doing custom hardwood furniture, some of those details that take forever to do by hand or manually by power tools, pleh..... time is money.

[voltsandbolts]

Glidergider,

What’s the O.D. on the new router? I am making a set of similar mounting brackets for a Craftsman router I was given, plastic body with a 3.8” O.D. The thing was never used. I plan to use the crap out of it until it crokes, then I might go for one of the Porter Cables.

[Glidergider]

I'm not home to measure, but from memory, my craftsman router is 3.8in dia. the hitachi is 3.3in dia.

[edo]

Good looking plaque. Great to see you're up and running.

I suspect the problem you had with the cutting board is the router running at too high of a speed and/or cutting at too slow of a rate. Try it again when you with the variable speed router running at a slower speed. Friction from the high speed causes the melting. I've had real good results with 1/2" cutting boards and thought they were made from HDPE.

I won't ask about the "switch inadvertently broke".