Handcut Joes in Sydney, Australia

[Reflow]

So three months have gone by since I started this project but I have been pretty slack about starting a thread. In that time I have made reasonable progress building the base table, the gantry, and the Z carriage so that I have a rolling X and Y axis. To those with a kit cut by Joe, I can't express how lucky you are because it is a lot of work if you want to cut one by hand, I can assure you.

Here in Oz we have a random mix of metric and imperial materials, to the stage where a sheet of MDF has a metric thickness (3,6,9,12,16,18mm) and imperial dimensions 4'x8' for a full sheet. So I have been building a mostly imperial machine, adjusting only where necessary for metric (thicknesses of the MDF). This leads to only very minor modifications to Joes machine. The cut-outs in the torsion box pieces need to be narrowed, as well as the slots in the sides of the Z carriage, but otherwise things are much the same.

The whole machine has been cut with a jigsaw and a cheap-o router, the pair costing AU$100 total. The process has been to print a 1:1 template, stick it down to a 6mm MDF template, and use this to cut out all the repetitive pieces from thicker materials. For the more complicated parts such as the sides of the Z carriage and the gantry walls (which need slots routed) I glued the prints directly to the parts. Now I'm stuck trying to get them back off again with a razor blade so I can paint.

This is probably enough ramblings for one post, hopefully a few photos of the build are attached.

--Scott

[epineh]

Looks like you are off to a great start, keep em comin

Russell.

[Reflow]

A couple of blurry phone photos of the X and Y axis assembled.

Since taking these I have glued the skins to the big torsion box and given all the boxes a coat of shiny white paint. The gantry walls and the end plates are next but I need to sort out lead screws first before I paint over my centre marks.

[Greolt]

Good start Scott

Wonder if this is the first "Joe's 2006" made in Australia?

Greg

[Reflow]

Originally Posted by Greolt Good start Scott Wonder if this is the first "Joe's 2006" made in Australia? Greg

I don't know of any others, but I believe the race is on between Claudio and I to finish one.

I had considered I might have been able to cut him one by the time he got back from the states (with Joe's permission). But as always these things take longer than expected.

I'm jealous of all the stuff he brought back: http://www.cnczone.com/forums/showpo...2&postcount=12

--Scott

[joecnc2006]

Very nice job with hand tools.

the gantry walls ar you going to have the outer side wall pieces cut and glued together, it is two thick on each side, then just reinforce the walls after machine built.

Joe

[Reflow]

Originally Posted by joe2000che Very nice job with hand tools. the gantry walls ar you going to have the outer side wall pieces cut and glued together, it is two thick on each side, then just reinforce the walls after machine built. Joe

Cheers.

Yeah i didn't notice they were missing in the photo, you can actually see the outer pieces sitting to the right of the machine. Since I had no way to cut a decent round pocket, they are not pocketed and the pipes are 1/2" shorter across the gantry instead. I have since glued then together and it is all pretty solid.

The hardest part about hand cutting has been the bearing adjustment plates, it is really hard to cut them exactly right without any slop. They will be the first thing to re-cut once I have the machine running.

[ClaudioG]

Originally Posted by Reflow I don't know of any others, but I believe the race is on between Claudio and I to finish one. I had considered I might have been able to cut him one by the time he got back from the states (with Joe's permission). But as always these things take longer than expected. I'm jealous of all the stuff he brought back: http://www.cnczone.com/forums/showpo...2&postcount=12 --Scott

No need to get worried Scott, you're way ahead of me. I've just done the easy bit by shopping for parts and have some renovations to finish before I get started on this project.

Your machine is coming along great.

Maybe I'll have to lend you my ACME's so you can cut the parts for me

Cheers

Claudio

[bp092]

Nice work, especially doing it manually. Templating is definitely the way to go. Building joe's machine manually is a lot of work but completely do-able. Can't wait to see the videos to come when you fire it up.

[Greolt]

Scott and Claudio

I know you are past this stage and have the cutting pretty much done but did

you consider getting the MDF components cut by a comercial CNC operator?

I wonder if anyone has done a costing?

I am thinking mostly of in Australia where getting the precut components shipped over from Joe is cost prohibitive.

It might be something that would assist people who are thinking about a Joe's but are concerned about all the cutting to jump in.

Greg

[ClaudioG]

I am keen on getting the parts cut via CNC, either through another hobbiest or a commercial operator.

The first step is to convert Joes plans to metric thickness MDF and HDPE which I am hoping to get help with from a friend of a friend.

Even though the manual cutting is possible, I'd be concerned about the effort involved and the accuracy of the end result.

Claudio

[Greolt]

Cladio I would have a bit of a dig around on the forum.

I am sure others have made these changes already.

Certainly worth having a search.

Greg