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Thread: Granite and steel gantry router

  1. #1
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    Default Granite and steel gantry router

    I am putting this in the wood router forum even though I plan on cutting metal and wood with this machine. Here is my progress so far.

    I started with a 24x36x4 granite surface plate. It came from KBC tools and cost about $370 including shipping. I built a stand for it out of 2x4 wood and 3/4 inch particle board. The surface plate is supported at 3 points only. This forms the base of the machine and it was used to lap the other parts flat. I also indicated against this plate to straighten the linear rails.
    .Granite and steel gantry router-img_20181107_193442-jpg

    The gantry is built from a piece of 8x8x27 inch steel tube with a 1/2 inch wall. I bought ground strips of mild steel and grouted them to the gantry tube with a mix of epoxy and 220 aluminum oxide grit. The ratio was about 75 percent aluminum oxide and 25 percent epoxy by volume. The mix was a little thicker than chunky peanut butter. The ground steel strips were placed against the surface plate to force them to be flat. Spring washers were stuck in the epoxy to provide uniform force to hold the steel strips flat to the surface plate. I used xylene to clean all surfaces to be grouted and roughed them up as well with a sander. I added concrete blocks to increase squeeze out.

    .Granite and steel gantry router-img_20181119_192530-jpg Granite and steel gantry router-img_20181119_193820-jpg

    After the epoxy set I flipped the tube and measured the flatness of the steel strips with an indicator. It was out by about 0.002 inches. I decided to lap it the rest of the way. I tried using a small surface plate and two sheets of sand paper but the flatest I could get was about 0.0015 inches probably due to my technique. I decided to lap the gantry against the big plate to get it flatter. I glued four sheets of 100 grit paper to the big plate and lapped for about 20 minutes. This got me to better than 0.001 inches of total flatness. I finished lapping with a sheet of 220 on the smaller plate (not pictured) and got a nice finish and about 0.0007 inches to total flatness error. I decided to stop at this point.

    Granite and steel gantry router-img_20181124_190457-jpg Granite and steel gantry router-img_20181124_221915-jpg

    Next was mounting the X master rail. I moved the tube to the floor and brought the drill to it. I temporarily clamped the rails to the tube and used a transfer punch to mark the hole locations. I drilled and tapped the holes in an afternoon. The drill needed to be sharpened a few times because of the aluminum oxide and epoxy layer. I used 5/16-18 bolts to mount the HSR30 rails.

    Granite and steel gantry router-img_20181125_175453-jpg

    Once the holes were tapped, the tube was put back on the granite table and the master rail was indicated in. I got it straight to better than 0.0003 inches. Once the master rail was attached I verified its flatness with the smaller grade A surface plate. The needle on my 0.0005 inch indicator did not move much at all.

    Granite and steel gantry router-img_20181126_183600-jpg Granite and steel gantry router-img_20181126_183631-jpg

    Continued in the next post because I hit the 8 image limit...

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    Granite and steel gantry router-img_20181124_221915-jpg   Granite and steel gantry router-img_20181125_175453-jpg   Granite and steel gantry router-img_20181126_183600-jpg   Granite and steel gantry router-img_20181126_183631-jpg  

    Last edited by multivactubes; 12-05-2018 at 01:44 PM.


  2. #2
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    Default Re: Granite and steel gantry router

    Next I indicated the second X rail using the master rail as a guide. I got these parallel to about 0.0002 inches I estimate.

    Granite and steel gantry router-img_20181126_194138-jpg

    With the X axis rails mounted I moved on to the the Z axis mounting plate. I used 1 inch thick cast tooling plate to build the Z assembly. The plate is flat to about 0.002 inches over its 16 inch length. I may lap it at a later time but I have yet to see it cause any problems. I printed a paper template and glue it to the plate. I then used a punch to mark each hole and drilled all the holes with a drill press. My drill press has a reverse switch and a momentary run switch so I can easily power tap. The Z rails are NSK LH25 rails and mount with 1/4-20 bolts. I used a gun tap to thread the holes.

    Granite and steel gantry router-img_20181128_184722-jpg Granite and steel gantry router-img_20181128_195719-jpg

    I mounted the Z axis plate to the X axis rails and then mounted then Z axis linear rails to the plate. I used the smaller granite surface plate to indicate the master Z rail in then indicated the secondary rail in from the master. Like the X rails these Z rails are quite straight. I squared the Z to the X axis at this point using a ground angle block and my indicator. I did this by rotating the Z plate slightly and sweeping the indicator back and forth against the angle block. I acheived a squarness of about 0.001 inches over 6 inches and decided this was good enough. I then tightened the Z axis plate against the X axis trucks.

    Granite and steel gantry router-img_20181128_200516-jpg Granite and steel gantry router-img_20181128_203755-jpg

    At this point I tried sliding the Z assembly along the X rails and noticed no binding. You can feel the preload in the rails though and it takes a little force to move across the X travel.

    I then started on machining the spindle mounting plate. I made a paper template once again and drilled and tapped the needed holes. This plate required counterbores and machining as well which was done on my X2 mill. I ended up breaking a plastic gear in my X2 and had to rebuild the spindle during this job. I replaced all the gears with metal and swapped the bearings to sealed versions as well.

    Granite and steel gantry router-img_20181201_164841-jpg Granite and steel gantry router-img_20181201_185045-jpg

    I mounted the spindle plate to the Z axis rails and checked for binding but did not find any. I made another paper template and drilled the holes in the spindle clamp. The back of the spindle clamp was lightly lapped and then the spindle was attached to the spindle mounting plate.

    Granite and steel gantry router-img_20181201_185853-jpg

    Continued in next post....

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20181126_194138-jpg   Granite and steel gantry router-img_20181128_184722-jpg   Granite and steel gantry router-img_20181128_195719-jpg   Granite and steel gantry router-img_20181128_200516-jpg  

    Granite and steel gantry router-img_20181128_203755-jpg   Granite and steel gantry router-img_20181201_164841-jpg   Granite and steel gantry router-img_20181201_185045-jpg   Granite and steel gantry router-img_20181201_185853-jpg  

    Last edited by multivactubes; 12-05-2018 at 01:48 PM.


  3. #3
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    Default Re: Granite and steel gantry router

    Nice work.

    Gerry

    UCCNC 2017 Screenset
    [URL]http://www.thecncwoodworker.com/2017.html[/URL]

    Mach3 2010 Screenset
    [URL]http://www.thecncwoodworker.com/2010.html[/URL]

    JointCAM - CNC Dovetails & Box Joints
    [URL]http://www.g-forcecnc.com/jointcam.html[/URL]

    (Note: The opinions expressed in this post are my own and are not necessarily those of CNCzone and its management)


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    Default Re: Granite and steel gantry router

    Here is what the gantry looks like with the spindle test fit.

    Granite and steel gantry router-img_20181202_171743-jpg

    I had a small company machine the ballscrew mounts for me as well but his tollerance was very loose so I am having to remachine many of the important surfaces and use some shims. I may recut all these parts with the machine once it's made. Here is a test fit of the X asis screw. The X and Z screws are THK 2005 ground ballscrews. The fixed end supports are Kuroda FK15 preloaded angular contact bearings.

    Granite and steel gantry router-img_20181205_075800-jpg

    I sent a drawing of the gantry support legs to a fabricator as well and am waiting for them to be made.

    Granite and steel gantry router-screenshot_20181205-115445-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20181202_171743-jpg   Granite and steel gantry router-img_20181205_075800-jpg   Granite and steel gantry router-screenshot_20181205-115445-jpg  


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    Default Re: Granite and steel gantry router

    Your machine is going to be awesome mate, keep up the progress!



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    Default Re: Granite and steel gantry router

    Here is where I am at on the Z ballscrew assembly. I finished the machining on the mounts. I also cut the ballscrew to length which was not easy. I tried to part it off on the lathe but it was far too hard. I tried a carbide tool as well but that did not make much progress either. I ended up grinding through it and used a damp rag to keep it cool.

    I used the indicator again to align the screw to be parallel to the rails to within about 0.002 inches. I tested the Z axis by driving the ballscrew with a drill and did not detect any binding.

    Granite and steel gantry router-img_20181209_194259-jpg
    Granite and steel gantry router-img_20181209_194220-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20181209_194259-jpg   Granite and steel gantry router-img_20181209_194220-jpg  


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    Default Re: Granite and steel gantry router

    I completed the mounting of the X axis ballscrew.

    Granite and steel gantry router-img_20181216_161054-jpg

    The welded support columns came in as well and I am getting ready to turn them flat.

    Granite and steel gantry router-img_20181216_161040-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20181216_161054-jpg   Granite and steel gantry router-img_20181216_161040-jpg  


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    Default Re: Granite and steel gantry router

    I had some time off for the holidays so I made a decent amount of progress on this machine. The columns were put in the lathe chuck and the end plates were skimmed flat and square to the 5x5 inch tubes.




    I lapped the ends of the columns as well so they will make good contact with the granite machine base.



    I machined a custom tool to tighten the nuts that hold the ballscrews to the angular contact bearings.



    Next I worked on the motor mounts. There are turned aluminum spaces 2.25 inches long. The couplers are Oldham style.

    Granite and steel gantry router-img_20181223_003126-jpg

    I tapped holes in the gantry tube to mount the columns as well and I did a mock-up to see how it looks assembled.



    I am getting missing steps at some speeds maybe due to resonance issues. This will have to be fixed before I use the machine. I have had it up to 120 IPM even with these issues and it does not seem to be binding. I may order some hybrid stepper motors and boost the voltage to see if I can stop the missing steps. Right now I have 415 in/oz steppers which don't produce much torque at speed.

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20181223_003126-jpg  


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    Default Re: Granite and steel gantry router

    Next was the hard part- drilling 38 holes in the granite plate. I used a 14mm sintered diamond drill I bought on eBay. After 38 holes it still has plenty of life left. I made a hole in a piece of tile not pictured and used it as a guide to start each hole. I used the HSR 25 rails as a guide for a transfer punch to mark each hole location on the granite.

    Granite and steel gantry router-img_20181229_165434-jpg

    I drilled each hole submerged in water. I took a pvc fitting and machined one side flat and stuck this cup to the granite with grease for each hole. The cup was then filled with water.


    Granite and steel gantry router-img_20181229_194520-jpg
    Granite and steel gantry router-img_20181229_205550-jpg

    The rails and clounms seem like they will fit.

    Granite and steel gantry router-img_20181230_190540-jpg
    Granite and steel gantry router-img_20190101_195421-jpg

    I turned 28 of these inserts so far. They are 1/4-20 coupling nuts that I turned mostly round and knurled to increase grip. I am not any good with knurling so some of the inserts have a course pattern and some are fine.

    I left some of the hex intact on each insert to provide resistance to pull out and twisting.

    Granite and steel gantry router-img_20190101_195520-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20181229_165434-jpg   Granite and steel gantry router-img_20181229_194520-jpg   Granite and steel gantry router-img_20181229_205550-jpg   Granite and steel gantry router-img_20181230_190540-jpg  

    Granite and steel gantry router-img_20190101_195421-jpg   Granite and steel gantry router-img_20190101_195520-jpg  


  10. #10
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    Default Re: Granite and steel gantry router

    Nice work. Where did you get your granite slab?



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    Default Re: Granite and steel gantry router

    Quote Originally Posted by 1Jumper10 View Post
    Nice work. Where did you get your granite slab?
    Thanks. The granite came from KBC tools. It cost about $370 including shipping. Grizzly is a good option too for about the same price but they were out of stock at the time I ordered.

    Here is a progress update:

    I cleaned each hole in the granite with a vacuum, then water, then acetone, then vacuumed again.

    I put 0.03 inch thick fiber washers between each insert and the mounting holes on the machined surface of the gantry support legs. The washers are used to force the inserts to sit below the surface of the granite.

    Granite and steel gantry router-img_20190102_201155-jpg

    I then mixed up some epoxy and added about 50 percent aluminum oxide power by volume. This mix is about like creamy peanut butter in that is will slowly flow and roughly self level.

    The process of epoxying in the inserts is done in two stages. First, a small amount of epoxy is put in each hole and the support columns and insert assembly is set in the holes. The amount of epoxy in the holes is limited so that there is no squeeze out to accidentally stick the support legs to the granite. After this first round of epoxy hardens the bolts are removed, the leg is removed, and a second batch of epoxy is applied to fully secure the insert.

    I clamped 123 blocks to the granite to help get the columns in the right place.

    Granite and steel gantry router-img_20190102_201215-jpg

    I also used a piece of angle iron to align the columns. At this point there is a small amount of epoxy in each hole and the inserts are hanging down into the holes.

    Granite and steel gantry router-img_20190102_212313-jpg

    Here it is the next day and I am applying the second round of epoxy from the top to fully secure each insert. I bought some syringes from McMaster to make applying the epoxy easier. The mix is the same as before - 50/50 epoxy and Al oxide grit.

    Granite and steel gantry router-img_20190103_200025-jpg

    Here is what an insert looks like with all the epoxy added.

    Granite and steel gantry router-img_20190104_233909-jpg

    At this point I loosly mounted the columns and set the gantry on top to see what the machine looks like. You can see I am starting to get the Y axis rails in place as well.

    Granite and steel gantry router-img_20190105_195137-jpg

    Finally I set up guides, installed inserts, and poured the first round of epoxy to attach the Y rails.

    Granite and steel gantry router-img_20190106_200837-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20190102_201215-jpg   Granite and steel gantry router-img_20190102_212313-jpg   Granite and steel gantry router-img_20190102_201155-jpg   Granite and steel gantry router-img_20190103_200025-jpg  

    Granite and steel gantry router-img_20190104_233909-jpg   Granite and steel gantry router-img_20190105_195137-jpg   Granite and steel gantry router-img_20190106_200837-jpg  


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    Default Re: Granite and steel gantry router

    This is really awesome work.



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    Default Re: Granite and steel gantry router

    Quote Originally Posted by wizard View Post
    This is really awesome work.
    Thank you for the encouragement.

    Here is where I am at as of today:

    I did the second round of epoxy to secure the inserts for the Y axis rails two days ago.

    Yesterday I used a sharp chisel to scrap off the excess epoxy that ended up on top of the surface plate.

    Before
    Granite and steel gantry router-img_20190108_183324-jpg

    And after
    Granite and steel gantry router-img_20190108_184643-jpg

    Here is what the machine looks like with the Y axis rails loosly mounted. I did this as a test fit to make sure the inserts were all in the correct position. I have not yet straightened the rails but I did manage to get them parallel to better than 0.0003 inches as a test. I looks like all the inserts are placed close enough to the correct position that the machine will possible to assemble.
    Granite and steel gantry router-img_20190108_200438-jpg

    The next step will be to remove the gantry and legs so I can set the smaller surface plate on the table of the machine and use it to straighten the Y axis master rail.

    I am planning to tighten the bolts that go into the inserts to about 15 inch pounds. This should provide about 300 pounds of clamping force per screw.

    I am considering ordering a set of these nema 24 closed loop steppers and high voltage drivers for the machine.

    https://www.ebay.com/itm/NEMA24-4-5N...t/173695019986

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20190108_200438-jpg   Granite and steel gantry router-img_20190108_183324-jpg   Granite and steel gantry router-img_20190108_184643-jpg  


  14. #14
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    Default Re: Granite and steel gantry router

    That workmanship is positively awesome. You have a lot of patience :-)



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    Default Re: Granite and steel gantry router

    Very early in my career I worked on lathes for the turning of optical parts. They used inserts in a very similar way to your build. That is they where glued in place. I’m not exactly sure how that was done and in this case they bolted down cast iron plain bearing slides. In any event we got plenty of warnings about avoiding excessive torque on any screw going into an insert. Your inserts look fine for 300 pounds of pull.


    In any event keep up the good work.



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    Default Re: Granite and steel gantry router

    I have gotten bad about taking pictures as I work. The machine mostly looks completed at this point so I guess there is not too much to show. I installed the Y rails to about 15 inch pounds of torque per bolt. I used the smaller grade A surface plate I have to straighten them to better than 0.0005 inches over their length. I also got both Y rails parallel to better than 0.0005 inches.

    Granite and steel gantry router-img_20190109_205336-jpg

    I alinged the gantry tube using three jack screws that stick down through the bottom of the gantry tube and rest on top of the support columns. This was a little tricky as the gantry needed to be alinged in three different dimentions at once. I used my angle block and an indicator to tune the position of each screw until I had an error or less than 0.0005 inches per 6 inches in X and Y directions. The Z axis error is about 0.001 inches over 6 inches.

    I left a gap of about 0.1 inches between the columns and the ganrty tube. I filled the gap with the same epoxy grout as before except I used a dryer mix this time of about 35 percent epoxy and 65 precent al oxide grit.

    Granite and steel gantry router-img_20190113_143352-jpg

    The epoxy needs to cure for another day or so and then I will check the alignment again.

    I bought a THK 1510 ground ballscrew from eBay and set it on the table to see what it looks like. It feels preloaded.

    Granite and steel gantry router-img_20190113_193518-jpg

    I also ordered a piece of aluminum tooling plate for the table. It is 13 x 15 x 1.5 inches.

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20190109_205336-jpg   Granite and steel gantry router-img_20190113_143352-jpg   Granite and steel gantry router-img_20190113_193518-jpg  


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    Default Re: Granite and steel gantry router

    The next step was drilling the holes for the Y axis screw. I made a smaller stone guide than I used before and started each of the four holes that I needed. I used the same drill and bit as before and took my time so that I did not crack the granite for the two holes that are near the edge of the granite.
    Granite and steel gantry router-img_20190120_152802-jpg
    Granite and steel gantry router-img_20190120_154048-jpg

    Here is the machine with the holes drilled and the table set in place. Maybe I should have only made the table 1 inch thick?
    Granite and steel gantry router-img_20190120_162538-jpg

    I added inserts and epoxy to the holes in two stages as I explained in an earlier post.
    Granite and steel gantry router-img_20190122_191905-jpg

    The new motors and drivers came and I fitted them to the machine. These are NEMA 24 closed loop steppers with LCDA86 drivers. I am using a power supply that puts out about 57V. I have tested the Z and X axis so far with these motors and drivers and acheived 8000mm/minute without missing steps. This is far faster than I expected and I think faster than I need. I probably will end up setting my max speed to 6000mm/minute.
    Granite and steel gantry router-img_20190123_212854-jpg

    Here are the internals of the LCDA86 driver. Note that what the eBay seller sent me is not exactly what was in the eBay pictures and description. The drivers I received are rated at 80V max and take DC only. The seller described them as 100 V max drivers that also accept AC. I emailed the seller and they told me the difference was just a missprint on the silkscreen on the housing and the drivers they sent could be used up to 100V. There is not rectifier in these drivers though so they can't accept AC. This leads me to believe the seller is wrong and they actually sent the wrong drivers. Regardless, these drivers do work well. I don't think I will push them past 80V however.
    Granite and steel gantry router-img_20190122_195539-jpg

    The eBay pictures say 100V max and accept AC. What I actually received is pictured below.
    Granite and steel gantry router-img_20190123_212111-jpg



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    Default Re: Granite and steel gantry router

    Here is a small progress update:

    I aligned the Y axis screw to better than 0.0005 inches with respect to the linear rails and tightened the bolts.

    I also made a ballscrew mounting bracket. I used a boaring bar and the lathe to cut the large hole and used my X2 mill to cut the block to size and drill the holes. I lapped this part as well to get the two mounting surfaces flat and square.

    Granite and steel gantry router-img_20190124_211500-jpg

    Next, I cut and lapped some 1 inch round aluminum stock in to 4 pieces that are each 8 mm long. This is the disctance that the table needs to be temporarily raised in order to clear the ballscrew nut and bearing blocks. I used super glue to attach these spacers to the linear rail trucks.

    Granite and steel gantry router-img_20190127_194911-jpg

    I set up some guides to get the table correctly aligned with respect to the rails. I coated the top of each spacer and the ball nut mount with super glue then dropped the table in to place. I later measured its squareness at about 0.003 inches over its 15 inch length.

    Granite and steel gantry router-img_20190127_201305-jpg

    I have not yet permanently mounted the Y axis motor so it is clamped to the granite for now. The timing belt is GT3 5mm pitch.

    Granite and steel gantry router-img_20190130_180229-jpg

    I mounted my new closed loop stepper drivers and break out board to a piece of plywood. With this setup I got to 6000mm/minute on all three axes.

    Granite and steel gantry router-img_20190130_180218-jpg

    The next step will be to use the machine to drill starter holes for the permanent mounting bolts for the table. Since this machine is the only thing I have that is large enough to drill and machine the table I plan on using it as much as possible.

    Granite and steel gantry router-img_20190130_180252-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20190130_180252-jpg   Granite and steel gantry router-img_20190130_180218-jpg   Granite and steel gantry router-img_20190130_180229-jpg   Granite and steel gantry router-img_20190127_201305-jpg  

    Granite and steel gantry router-img_20190127_194911-jpg   Granite and steel gantry router-img_20190124_211500-jpg  


  19. #19
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    Default Re: Granite and steel gantry router

    I am way behind on posting an update to my build.

    Here is the table temporarily mounted with 8mm spacers holding it off the linear rail trucks.

    Granite and steel gantry router-img_20190202_164459-jpg

    Here the clearance for the ballscrew is being machined out. It is 8mm deep. This was the first real machining I did on this machine.

    Granite and steel gantry router-img_20190202_215035-jpg

    Here the table has been flipped, counter bored, and mounted.

    Granite and steel gantry router-img_20190203_152059-jpg

    I did circular interpolation to machine the grid of holes that will be threaded. They are on a 2 inch grid. I removed the spindle and used a high torque drill to tap each hole. I used the machine to cut a plywood disk to go where the spindle usually sits. This provided a guide to keep the tap straight.

    Granite and steel gantry router-img_20190208_193017-jpg

    I drilled two more holes in the granite and epoxied in inserts to mount the Y axis motor.

    Granite and steel gantry router-img_20190215_214614-jpg

    I added some sheets of clear vinyl to act as chip guards for the Y axis.

    Granite and steel gantry router-img_20190221_202837-jpg

    Here the table has been machined flat. The top of the table is parallel to the granite to better than 0.0005 inches after machining.

    Granite and steel gantry router-img_20190221_205159-jpg

    Attached Thumbnails Attached Thumbnails Granite and steel gantry router-img_20190202_164459-jpg   Granite and steel gantry router-img_20190202_215035-jpg   Granite and steel gantry router-img_20190203_152059-jpg   Granite and steel gantry router-img_20190208_193017-jpg  

    Granite and steel gantry router-img_20190215_214614-jpg   Granite and steel gantry router-img_20190221_202837-jpg   Granite and steel gantry router-img_20190221_205159-jpg  


  20. #20
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    Default Re: Granite and steel gantry router

    Awesome. We need a video



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