Dave's Build Thread

[kemper45]

I decided it was time to start documenting my build to hopefully share with others what I have learned. I know I have learned so much from spending many hours browsing the various build threads here. That and the fact Bill (bjesson) "shamed" me into getting on with the wood base portion of my build.

If you mentioned a CNC machine to me a year ago I would have said “what”? I first became interested through my other hobby which is building a “cockpit” for my flight simulator. I have made some very basic panels out of thin mdf and a drill and saw. Then I saw what others were making with their CNC machines and I was hooked. So off I went on an internet research mission and stumbled upon the Momus CNC Router. I liked some of the parameters Bob described (self contained, build with everyday tools, detailed instructions) and for $20 what could I lose. Easily the best $20 invested on this project this far.

Next step was putting together a budget based on the detailed parts list. Again back to the internet looking for sources of the various pieces as I was coming into this with basically nothing. I also decided to invest in a very basic drill press at this time as well as putting together a simple but solid workbench. Then it was a matter of waiting for the aluminum and steel to show up and the real work could begin.

Unfortunately I don't have many photos of the metal portion of my build. In fact I only have one which is included below. One of the keys to the build of this part of the machine was the fact that I took my time. I went into this whole project with the mind set that I was going to be patient with the process. When people would ask me how long will this take I would tell them I expected to be at it for a year!! Now some of you guys may think I am crazy but that was my approach. I would head down to my workbench (note I didn't say workshop because it isn't anything more than a bench) on any given night and start to measure, mark, cut, drill, tap, etc. I would be happy to get a piece or two each night and then move on. Even at this pace I still managed to make a few small errors but nothing serious.

The other factor for me was having access to a friend of the family who is an excellent machinist with a workshop and tools that any one would drool over. He was very willing to help telling me to come by whenever I wanted. He fabricated the more complicated pieces including the router clamps for me which was a huge bonus.

Actually since I took the photo I have added a couple of the motors to test fit them. I went with the 3 axis package from cncrouterparts because I was looking for a "one stop" shop. I started out planning to use the Xylotex set up that Bob used in his build but as I did my research I changed my mind. I was sold on a couple of things about this package :

1. The Gecko 540 drive board seems to be almost "indestructible" which was important to this electronics challenged builder. I always hold my breath when I flip the switch of anything I put together expecting the magic smoke to come billowing out at any time.
2. The premade motor cables fall into this category as well considering the need otherwise to solder resistors in place. I have learned to solder a little for my flight sim hobby but when the chance for a pre-made cable was offered I went for it.

I realize this approach cost me a few more dollars but it was still within my budget. Well it was pretty close.

Today, I fired up the table saw and started to make some sawdust. Got lucky and was able to cut some pieces for the base in the process. Just finished the initial glue up of the base torsion box as shown in the other attached photo. Again slow and steady pace but hopefully not as long as the gantry and carriage parts. Of course tomorrow being Mother’s Day may slow down the process a wee bit.

Looking forward to sharing the rest of my building experiences as I make progress. As well I expect I will have more than a few questions to ask others as I get into the electronics, Mach 3, g-code, etc.

Cheers, Dave

[revwarguy]

Hi Dave,

You won't regret getting the G540, even if they are a chunk of your budget initially. They do many things to make the process much smoother. If you have any questions about the wiring, etc, just ask.

I haven't built this design, although I do have the plans and am thinking about doing one for just metals. I did build my CNC machine (you can read about it here if you want) and used the G540 and am very happy with the results. I have cut wood, aluminum, and several plastics with very nice finishes. Don't forget to budget for software, depending on what you want to make with it.

I am also interested in a simpit. Haven't started, but probably do a modern fighter style since the instrumentation is easily done with flat panel displays. Always thought the CNC would not only be good at making the pieces fit well but also in making the skins look faceted and riveted, etc. Any pictures of your current sim on the net?

You also won't regret having a drill press, either. You might want to make table for it, unless it already came with a good fence. In any case, the work you've done so far looks great for never having owned a drill press before! One thing you just have to get comfortable with - building a CNC is an excuse to buy more tools!

You are also absolutely right to take your time - enjoy the build process! It won't be all that long before you will be wanting to build another!

[kemper45]

Revwarguy,

Here is a link to thread at a flightsim forum that shows a couple of pics of my build under construction (post #32)

Show Us Your GA Pit!

Like this forum, lots of good folks there to help out fellow builders.

Already had your site book marked from a previous post somewhere and have referred to it a few times.

Thanks for the compliment on my build so far. I am enjoying the learning aspect of this as much as anything and look forward to the day I make my first chips. As for tools I only had a Craftsman circular saw about 20 years old until I got the drill press. I have now also added a great old Beaver table saw and am on the look out for more tools. Next step is to find a place to set all this stuff. Fortunately my father in law has a well equipped shop and is always willing to help.

As for my build I finished the torsion box base today and plan to continue with it this week. Need to pick up some more plywood first.

Dave

[bjesson]

LOOKIN GOOD DAVE!

Let's not talk about flightsims anymore Mine "crashed" when the first daughter was born My brother in law is a rocket scientist and knows a lot of people in the airforce so he would take me to the AF base to "fly" the F16 training sims...heaven. The best one was the front half of an F16 you climbed in and the canopy was covered in screens so you had the full view. The entire sim took up a warehouse!

Looks like you are approaching the top of the hill!! Things will speed up now that you have all the hard parts of the base glued.

Lookin forward to seeing more pics!

billj

[bjesson]

I may have to one up ya though. I ordered an anodizing station last week and may use it to match my aluminum parts with the base color scheme

At this point it would have been cheaper to pay someone to make the parts I built the CNC for and then pay someone else to plate them. Oh well, I have it all now so after this guitar sells I will have turned a profit as well as paid off all the purchases I have made to feed my hobby.

billj

[revwarguy]

I ordered an anodizing station last week and may use it to match my aluminum parts with the base color scheme

Bill, you mind sharing with us a link to what you selected?

[bjesson]

I ordered an anodizing station last week and may use it to match my aluminum parts with the base color scheme

Bill, you mind sharing with us a link to what you selected?

Here is the kit, I didn't need the tanks since I still have a big station from my early days of nickel/chrome/copper plating but the rest of the stuff in the kit makes it a bit easier then trying to buy the parts individually.

Caswell Inc. - LCD Aluminum Anodizing Kit

Link to the dyes:
Caswell Inc. - Anodizing Dyes

And as I was typing I received the UPS ship notification so it will all be here in 5 days!!

billj

[kemper45]

This isn't really a build update but a material acquisition which is part of the overall process right. Plus it is too good a story not to pass on and since my wife wasn't impressed you guys get to hear it.

Starts out as a "sometimes things happen for a reason" type of story. For some unknown reason when I purchased my plywood a few weeks back I only bought two sheets of 3/4" plywood. Still can't figure out that happened. So on the weekend as I am making some headway I run out of material and needed to shut it down.

Tonight, rather than head back to the building supply store which is a good half hour away, I decide to head to the orange big box. Take a look at their 2x4 plywood but it is all construction grade if that. Contemplate buying a 4x8 sheet of G1S plywood even though I only need a quarter of it. My frugal side kicks in and I decide to wait until tomorrow and head to the building supply place. On my way out I am passing by the cutting area and decide to wander in. Sure enough there are 2 part sheets of 3/4" maple plywood, jack pot.

I go looking for the "lumber guy" and eventually track him down and head over to look at the sheets and see what is up. I ask him if they are being held for somebody. He tells me no so I ask him what they would cost. He tells me he can't sell them to me as they don't belong to the store - they are left over from some material that was cut for another customer. When I ask him if the customer is returning for them he tells me no. So what happens to them? I ask. His response - we will throw them out. They won't sell them to me because it is not their material any more. Fine I say, what time are you going to the dumpster and I will meet you there. Guy laughs and says sorry that is the direction he has from the manager. Luckily we have done some recent renovations to the house and I have a working relationship with the assistant manager and she is in tonight. Quick chat with her and the lumber guy and next thing I know I am headed out the door with a 29"x44" and a 29"x52" sheet. Total cost, $3.39 taxes included. Best part - manager says to me as I am leaving, she would have told me to just take them if the employee had not been involved.

And now back to the table saw to make more sawdust. Don't know if that one ups Bill's anodizing station but still one heck of a deal (or is it a steal).

Cheers, Dave

[bjesson]

This isn't really a build update but a material acquisition which is part of the overall process right. Plus it is too good a story not to pass on and since my wife wasn't impressed you guys get to hear it.

Starts out as a "sometimes things happen for a reason" type of story. For some unknown reason when I purchased my plywood a few weeks back I only bought two sheets of 3/4" plywood. Still can't figure out that happened. So on the weekend as I am making some headway I run out of material and needed to shut it down.

Tonight, rather than head back to the building supply store which is a good half hour away, I decide to head to the orange big box. Take a look at their 2x4 plywood but it is all construction grade if that. Contemplate buying a 4x8 sheet of G1S plywood even though I only need a quarter of it. My frugal side kicks in and I decide to wait until tomorrow and head to the building supply place. On my way out I am passing by the cutting area and decide to wander in. Sure enough there are 2 part sheets of 3/4" maple plywood, jack pot.

I go looking for the "lumber guy" and eventually track him down and head over to look at the sheets and see what is up. I ask him if they are being held for somebody. He tells me no so I ask him what they would cost. He tells me he can't sell them to me as they don't belong to the store - they are left over from some material that was cut for another customer. When I ask him if the customer is returning for them he tells me no. So what happens to them? I ask. His response - we will throw them out. They won't sell them to me because it is not their material any more. Fine I say, what time are you going to the dumpster and I will meet you there. Guy laughs and says sorry that is the direction he has from the manager. Luckily we have done some recent renovations to the house and I have a working relationship with the assistant manager and she is in tonight. Quick chat with her and the lumber guy and next thing I know I am headed out the door with a 29"x44" and a 29"x52" sheet. Total cost, $3.39 taxes included. Best part - manager says to me as I am leaving, she would have told me to just take them of the employee had not been involved.

And now back to the table saw to make more sawdust. Don't know if that one ups Bill's anodizing station but still one heck of a deal (or is it a steal).

Cheers, Dave

LOL, see I would have been just as excited about that story as you and my wife would have listened to the whole thing but not paid any attention. A friend of mine just redid their entire house countertops in granite and had a 12 foot slab left. They spent $10,000 on the granite and had about $3000 worth left over. They kept the extra because they didn't want to give the stone cutters anything for free. They also needed laundry room cabinets and offered me a trade, I build them cabinets they give me the 12 ft. by 4 ft. slab. I think the cabinets cost me $500 in materials and a few days to build. I am telling my wife this whole story, she has been bustin my ass to remodel our bathrooms, yet shows zero interest in the materials I get for dirt cheap!

WOMEN!

billj

[kemper45]

Well things are progressing at a tortoise like pace. Slow and steady. I have now attached the front and back plates and plan to install the side plate rib structures this week. In preparation for that I was double checking the front to back clear dimension between the plates and I stumbled upon something unexpected. At least to me it was.

I noted that the dimension at the bottom was spot on but the top dimension was 3/16" to 1/4" out (ie. greater than the bottom dimension). Since I am still a day or so away from the next step I threw a clamp on each side to pull the top of the plates into line with the bottom.

Don't know if any one else experienced this - maybe a consequence of my slow piecemeal approach to constructing the base. I thought it was worth sharing in case some one else runs into the same situation.

Dave

[louieatienza]

Well things are progressing at a tortoise like pace. Slow and steady. I have now attached the front and back plates and plan to install the side plate rib structures this week. In preparation for that I was double checking the front to back clear dimension between the plates and I stumbled upon something unexpected. At least to me it was.

I noted that the dimension at the bottom was spot on but the top dimension was 3/16" to 1/4" out (ie. greater than the bottom dimension). Since I am still a day or so away from the next step I threw a clamp on each side to pull the top of the plates into line with the bottom.

Don't know if any one else experienced this - maybe a consequence of my slow piecemeal approach to constructing the base. I thought it was worth sharing in case some one else runs into the same situation.

Dave

Possible your saw is cutting just a tad out of square. Might have to check with a good engineer's square or combination square.

A rafter/framing square might work, but I never trust them. You can check and "fix" them easy enough...

[kemper45]

Thanks for the suggestion Louie, I will double check my table saw.

Upon some reflection I think it is more a result of pulling the bottom of the front and back plates tight with the glue and nails. This causes the "posts" at either end to rotate outwards at the top. The clamps will hold them in place for now until I install the right and left ribs and plates.

Cheers, Dave