On 4/20/2015 5:41 PM, Jack Coats wrote:
> If you want to build something in that range, but have a larger and pretty
> rigid rig, consider Mechmate.com ... It is a real DIY project, normally
> uses NEMA 32 motors, but if you have some good 24's might work.  Still
> check out their forums.  Plans cost $100, normal build costs for everything
> go anywhere from $3K to $8 or 10K USD, depending on what you have and
> accountability in your area.

He's built a CNC router already, he should have the skill to build a 
metal framed one without needing to pay for plans. There's so much free 
info on the web and a large number of other DIY builds to snag ideas 
from... I also see plenty of "just add..." metal gantry router table 
kits on Craigslist. Those are usually built up from aluminum extrusion 
with a few custom CNC milled pieces for the gantry ends.

If the wood framed router is large enough and the main gripe is having 
to periodically snug up the bolts and some lack of rigidity - how about 
replacing the woodwork on your woodworking machine with metal?

If you don't have the tools to precision cut the parts, find a metal 
supply shop that can cut the pieces to exact lengths. Replace the main 
frame with steel and the gantry (assuming it is a gantry table) with 
aluminum for lighter weight.

Depending on how hefty the current gantry is constructed, the aluminum 
could end up lighter yet stiffer.

Shouldn't be difficult to design it so all the current drive system and 
electronics will directly transfer.

If the drives are by belt, chain or rack and pinion it would be 
relatively simple to make the metal version larger. Add more rack or 
chain links or buy longer belts. If it's screw drive then increasing the 
size gets costly quick due to needing new, longer screws. If only screws 
could be added onto like chains and racks...

If it's screw drive then I'd look into building an all new, metal frame, 
router then spiffing up the old one nice and tight and clean then 
selling it.

Y'know, I bet biscuit joints and some strategically placed metal corner 
brackets would keep the wood frame from loosening. 'Course then the 
parts would be permanently attached to each other.

https://www.youtube.com/watch?v=x6kIipnVVOc


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