Sinkoumn's JoesCNC2006 Build Log

[Sinkoumn]

Hi all, I figured since there haven't been too many new build logs put up I'd follow my build progress on the forum to share my experience building Joes CNC 2006.

I have been working on it for two days now, so here is where I am at with the build:

I had put an ad on craigslist to see if anyone in my area would cut out the parts - to my surprise I had about 8 offers to cut the parts. I wanted to order the parts through Joe, but do to limited funds at the time I decided to go with the local guy.

After all the nesting of parts here is what I ended up with, I saved the Rhino file to be opened in Adobe Illustrator and color coded the nested files for pocket depth cuts:
Pic 1: 8'x4' sheet - .5" MDF (sheet 1)
Pic 2: 8'x4' sheet - .5" MDF (Sheet 2)
Pic 3: 2'x2' sheet - .75" MDF
Pic 4: 2'x2' sheet - .75" HDPE
Pic 5: 1'x1' sheet - .5" HDPE
(Note, I left out the sheets that didn't have any pocketing)

[Sinkoumn]

Once all the parts were cut here is what I got:
(I should also point out that I have a friend that works for a hockey rink board company, and happened to have some red HDPE - so that's what the red parts are )

[Sinkoumn]

Of course there are always some mishaps, and in my case it was a weird case of internal shifting on a few of the parts. I don't know if this happened when the files were transferred over or what, but here is what the end results where on a few parts:
Pic 1: Holes line up, but pipe/rod holes are off-kilter
Pic 2: With the bolts in place to give a better idea of miscut
Pic 3: Hmm, looks a little off...
Pic 4: Again, center hole shifted off center (Z axis carriage)
Pic 5: So, as you can see the carriage is not center in terms of being level on the ground; however,
Pic 6: when you place the square on the internals of the carriage, everything is nuts on square.

Luckily the guy that I worked with to cut the parts is a stand up guy, he has been more than willing to recut any part that I need fixed - so I'm going to definitely get the CNC router end support plates (front and back) recut.

I am going to try and make the Z Axis carriage work. I think that it shouldn't pose any problem - I will likely just bore the rod hole that is off center to a larger diameter and install my anti-backlash assembly (reason being is that even though the center hole is off, the four bolt holes are right on; unless there is something I can't see, it should work out).

[Sinkoumn]

The next step was to dry fit everything, unfortunately I didn't take any pics of that until after I primed the parts:
Pic 1: Parts all layed out on cardboard ready to be painted (and of course I still got paint on the floor , oh well )
Pic 2: Gantry dry fitted
Pic 3: Same setup, different angle
Pic 4: Making sure the table is square when being glued up (the primer paint 'overspray' was removed shortly thereafter).

[Sinkoumn]

Next thing was to shine up the pipes and cut the angled aluminum- I ended up going with the black coated pipes from HomeDepot and managed to find the aluminum at Fleet Farm (every place I went (HD, Lowes, Hardware Hank, ETC) had 1"x1"x1/8" angled alum. or 1.5"x1.5"x1/8" angled alum. the 1.25" was tough to find).
Pic 1: My 'poor mans' setup - Lathe using the electric hand drill, table vise, small drill press table, clamp, and electrical tape
Pic 2: Hand drill with the electrical tape (held up like a rock I might add)
Pic 3: Here's how I made a cheap bearing - drilled hole through pipe cap (larger than outer diameter of bolt to be inserted), and then slid a bolt through with locking nuts (for the vice to grip), and a washer to let the pipe cap spin against)
Pic 4: What I started with, and what I ended with - not too shabby
Pic 5: Halfway done with the shining
Pic 6: Finished pipe

One thing that have still to do is treat the pipe with oil - can you use any style of oil or is gun blue the only way to go?

[Sinkoumn]

I don't have a radial arm saw or a table saw at my place (it's all up north at the cabin), so I had to use the good ol' sawzall and bench grinder to make the bearing slides. I measured everything twice and then cut it out on the table vise. Once all the parts were cut to length, I ground them down to drill the anchoring holes using the bench grinder at first (rough cut), then used a hand file to finish the job.

I am still waiting for my bearings to get here, so that process with be the next step with these plates once the parts get here, I just wanted to get this part of the build out of the way.

(One helpful note to any future builders - label your angled aluminum pieces to help tell them apart, they start to look a lot alike when they're all cut and sitting on the table , plus that way I know what piece goes with what plate (and what side goes to which))

Pic 1: My table/radial arm saw - SAWZALL
Pic 2: Test fit for length before final sanding
Pic 3: Anchor hole drilled and test fitted before final channel leveling with hand file
Pic 4: More test fitting into respective spots
Pic 5: X-axis bearing block installed and solid (slides, but doesn't twist)
Pic 6: Proof that I didn't goof and lodge the bearing block inside of the case

[Sinkoumn]

Gluing up the skins on the table, Y Axis gantry, Gantry torsion box, etc.
Pic 1: Getting excercise while building, carrying the plates in and out is a great way to work out without working out
Pic 2: Gantry torsion box
Pic 3: Y-Axis gantry box
Pic 4: Table fully glued and lined up with pipes

This is where I'm at for now. I am planning on finishing up my priming today, and continue to wait for my bearings. I'll keep posting my progress.

One thing I wanted to get some input on is the controller/power/etc. I was originally going to go with the Xylotex setup (for the ease of setup and being all prewired and whatnot), but after reading up on them I think I'm going to go with something else due to the problems a few people have had working with the Xylotex.

I've been looking at the HobbyCNC Pro package and the walkthroughs of getting them put together; I do have experience with soldering, but nothing past working with Xboxes and Playstations - does anyone know if the solder points are as fine as that type of work, or is HCNC board and the solder points fairly large and easy to work with?

Any input on a good all around package for power, controller, and motor size?

Thanks much!
Mike
Sinkoumn

[Mr.Chips]

Good looking build Mike and good pictures.
It's a real plus to build from Joes plans because it is a tried and true machine. It eleminates a lot of guess work and trial and error.

Keep up the good work.

[joecnc2006]

the build is coming along real good, keep us posted.

Joe

[Sbthomas13]

It's looking good so far! I like all the pictures and descriptions. Hopefully that Z Axis Carriage won't cause you too many problems...if the bearing block can be adjusted to account for the misalignment. I can't really tell what is quite wrong with it that causes it to not be square. You have to be careful and make sure that the Z axis rails aren't on an angle. Just make sure your bit is perpendicular to the table when you get to that stage.

[Sinkoumn]

Not too much done today, but something is better than nothing! I'm still waiting on the bearings so I can fully dry fit everything, so in the mean time I got the router holder all drilled/bolted, and actually proved that down time can be productive - by cleaning my shop!

But at the same time, after working for a painting company in highschool, I have to add that I HATE priming - worst part of any job

Pic 1: Rear plate - I had to modify/add-in the pockets because I goofed on the hole diamter in nesting
Pic 2: Another shot showing that miscalcutations can be controlled by having to do an extra step - in my case, clearing extra holes.
Pic 3: Finally snug, but really tempting me to paint the whole setup Red, White, and Blue.
Pic 4: My girlfriend kept checking herself over after I'd hang out with her, wonder why
Pic 5: Didn't clean off the work bench in two days, hopefully someone can relate to how quick messes pile up in the workroom
Pic 6: Luckily my bearings still aren't here so I had plenty of time to kill tonight - even was rambunctious enough to hit it with some scrubbing bubbles!

[Sinkoumn]

Thanks much for the reply on the build! I couldn't have done any of this without watching/reading/following all of the builds that you all have contributed to the site!!

Hopefully I can save up and start the 4x4 shortly this build is done! But that's tomorrow, so for now I'm content with getting this project up and running