View Full Version : aerojc first router

06-02-2007, 08:43 PM
as of today i started the real work on my first router.

ive been willing to have such a tool on my workshop for some years but didn't had the time or access to knowledge to go for one.

so this thread will work as a work log of my first machine.

electronics already on their way here, and the gantry started today.

06-05-2007, 10:53 AM
looking at the software side i gave a look at the linux Ubuntu distro with the EMC software already installed. but dont have the electronics yet to try it. does anyone have experience with that?

06-05-2007, 11:24 AM

I am using emc2 with ubuntu on my router.
Here is my thread. http://www.cnczone.com/forums/showthread.php?t=10425

There is also a section on emc here on the zone.


06-05-2007, 11:50 AM
looking at the software side i gave a look at the linux Ubuntu distro with the EMC software already installed. but dont have the electronics yet to try it. does anyone have experience with that?

I am using HobbyCNC with EMC2. I have also used my own driver with EMC2. I have talked to guys using a Xylotex driver. I have seen it used with many many other drivers.

Let me know if you need some hints configuring the ini files for EMC.

You could also check out my build log here:

06-05-2007, 11:54 AM
thank adam and acondit for your posts,

nice machines!

ill watch your threads by the night!

06-05-2007, 06:20 PM
made the first tests with the axis interface it looks quite nice, know ive to update to gcode and converting 2d/3d models into gcode, that will take time.

it doens't seem more complex than vb and c# buts its new.

since this project will go with paralell tasks its going to be a nice ride.

what do you use to convert a 3d model into gcode?

does anyone as a 3d model of a wing?

06-06-2007, 10:12 AM
I have have BobCAD... but it is not free, and support for 4-axis is lacking. GCAM on the open source scene is up and coming... might look into it.

I have never used it myself. I dont even know if it can accept 3d files yet.

06-14-2007, 09:31 AM
last night i finished the z axis, it looks good.

i could put the images in the post so you'll have to check them in the gallery


quality is low because they came from the mobile phone! next ones ill increase the definition.

06-14-2007, 08:24 PM
well two nights in a row, yesterday the z axis today the first linear bearing.

skate bearings are cheap 80 cents of an euro. the first test showed that we have a promise just with one it slides quite well, when finished i can imagine.

i also prepped the supports for the stepper motors.

reinforced the table with aluminum with t section. so i am moving.
still waiting for the electronics from motion control products, to start testing.

Ill keep you posted!

06-15-2007, 10:30 AM
weel it seems that motion control products is a good choice if youre living in portugal. they were fast in their delivery around 5 days.

bought the items directly in their online shop.

monday they are due in Portugal.

need to boost the fabrication. during the weekend to have the machine almost up and running during next week.

did anyone had problems with parallel port on ubuntu running the emc2 software?

kind of parallel port damage, i put this question since ill use my laptop for the job while i dont have my other machine ready for it.

another question would be did anyone use a old machine to do the job pII with clock speed of 500mhz and memory around 196 Mb?

06-15-2007, 12:34 PM
The machine I used is 450mhz with only 64mb of ram. With the lower speed computers there will be some minor latency issues, but that means you might not be able to run your machine at 80ipm without loosing steps.

I had no issues with the parallel port on ubuntu.

06-17-2007, 08:10 PM
well tomorrow its the day for the arrival of the electronics so. its time to speed up a bit.

today was the day to finish the second set of linear bearings, and to mount them into the X axis, i did some resizing of the z axis to enlarge the working area in the X axis.

i was going to post the photos on the gallery but i exceeded the amount of available memory, so ill post it on my personal server and leave here the link later.

adam, thank you for the information, im ok with the hardware that i have reserved for the machine a pIII w 500 mhz and 196 Ram.

another question.

preliminary tests of the Y axis showed that the material vs configuration used for the Y Axis is prone to quite some play, and that might force me to change the tube material. Any suggestion? im using steel tube of 16 mm or .62 Inch.

- the position of the stepper is defined by the position we determine as the origin right? im a bit confused about that, and if it relates with the workspace and axis orientation on cad programs?

thanks for the input til
some photos of the current updates


06-18-2007, 08:38 AM
Looks like you need some support for those rails. It is easier to add some support; even solid steel rod will flex a lot. I would suggest adding a back panel to your Y carriage to make it wrap around the Y rails (also add thin side panels for strength). Now move the Y screw to attach to this new back panel. This will free up the area between the two rails in order to add a support board running between them. This will in addition add support to the two gantry sides to keep them vertical. Many of us have used torsion boxes for this support beam to get a lot of strength without the weight.

Some examples can be seen in Lionclaw’s or Joes2006’s machines. Both of these machines have full drawings available for free. Here is a CAD of Lionclaw’s machine:

Good luck,

06-18-2007, 09:21 AM
thanks for the input steve.

i became aware of that during the weekend while trialling the movement in the Y axis. ill do that, seems quite simple and obvious.

im thinking of adding an extra line bearing, not as the one i used under the steel tube to avoid any play of the gantry, especially if i want to make the cutting speed faster, it seems that the gantry will try to come off.

update for today - received the electronics ill have another tasks starting electronics testing.

06-18-2007, 09:54 AM

It did look like the whole gantry could lift off the X rails in the pictures. You could use the same concept I mentioned for your X axis. Here is a link of Mike Hide’s solution. He is using angle iron, but pipe could also be used.



06-18-2007, 08:02 PM
night for trialling the electronics.

after some initial confusion, i managed to put the emc2 working with the break board supplied by motion control products.

after correction of the parport configuration file for the emc2, putting the pulses on the right pin and putting direction in the right pin all went as expected.

single step config and low amp peaks config. I have to study the bipolar parallel stepper arrangement to speed up the steppers.

now i must return to the fabrication, remake those y and x axis with a more reliable working!


06-26-2007, 06:04 AM
time to test the z xis for the first time attached the stepper into the unit a made go for a 100 units on the z G0 z100 and got 12,5 millimeters now i just have to find the a M8-1 screw to substitute the m8-1.25 i have. i also have to test the position file for the machine.

it looks good except for some play on the z unit.

can we invert the polarity of the motor to reverse the movement?

06-26-2007, 04:11 PM
weel and the end of the day i solve the movement by changing the input scale value to 160 after some calcualtions.

now ill go back to the x abd y axis.

07-08-2007, 07:49 PM
solved the gantry problems, made the torsion box.

rewired the z axis stepper to controler and made the first test.

she works.

i will try a cut in the next week!

any solution for the stepper to lead screws coupling!?? mine aint great!

07-08-2007, 08:31 PM
hey aerojc..
take any pictures of you machine lately?? just wondering..was wanting to see all the changes you've made :)

07-09-2007, 10:56 AM
any solution for the stepper to lead screws coupling!?? mine aint great!

Aerojc (John?),

I use Lovejoy L050 connectors for my stepper to leadscrew connections. Each connection require three pieces; (1) connector piece bored to fit the stepper shaft, (1) connector piece bored to fit the leadscrew shaft and (1) spider to provide the coupling between the two connectors. You can order them from Enco.


07-09-2007, 02:26 PM
well ace im just trying to convert 3gp format video to mov or wmv format, once ill have it done ill post it.

thanks acondit(alan) on the tip. ill go for it since my couplings are rigid one's and thats a no no, i just wanted to have it work for experience.

im still figuring out how to change the parameters of the emc2 to speed up things a bit and do a feed speed faster so im on the trialing and error phase.

well i must RTFM but does anyone know were to get a simple explanation on how to speed the feed cutting speed on the config file for the emc.

07-09-2007, 07:40 PM
well this was the day.

made my first test cuts with the emc2 axis file changed a bit the scale of the code and ran it.

the cuts are nice since they were done with a simple drill.

in the photos you can see the change i made into the y axis, last saturday night of fun with assembly of the motors and the first test making her write down, and the test cuts i made today with depron and the drill.

it aint much , and finally th z axis coupler gave way. so its time to improve with some lovejoy's from enco.

so the proteus machine is ready for experimentation, and to pave the way to the machine itself, as soon as i have time to plan it. that must be in the hollidays.

07-18-2007, 06:20 AM
well the z axis coupling is corrected for the meanwhile, ill order the lovejoys during the hollidays but it works fine for now.

whilke trying to convert some drawings made on autocad to ngc, I constantly find that the code as errors and i can't figure it out why.

ive benn using dakeng ace converter with no success, can anyone give me a help on this topic?

i was able to programa series of drill's um an array and even write the code to cut a former with arcs, but can't seem to find out wath the converter is doing!

08-18-2007, 01:14 PM
time to start the work, hollidays were nice, but its time to start the new structure after the first tests!

09-16-2007, 07:15 PM
its almost autumn and time to get back to work on the machine!

it was time for the limit microswitches to get cut from the board, a bit of salvaging from old mouses and they're done.

while i cant post the images ill serve them from my server

the limit switches! ready to wire and install

<img src="http://traquito.lasanha.net/havfun/files/DSC00192.JPG" style="width: 300px; heigth: 240px; "><CENTER></CENTER>

a new drill to take the place of a deceased one, with a routing bit from dremel

<img src="http://traquito.lasanha.net/havfun/files/DSC00193.JPG" style="width: 300px; heigth: 240px;"/>