5' x 5' CNC Router Build

Darren Wright

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Thanks guys!

Really coming along. Did I miss where you cut the little plates for the bottom of the legs?
I didn't catch a pic of the cutting, they were mentioned a couple of posts above with the gantry bearing plates, they were in the top of the pic with large X's on them. They are 1/4" plate, cut 3" x 3" to match the legs. I had marked them for drilling 9/16" holes through them for the leveling bolts to go through. I just did a quick stitch weld around all 4 sides when attaching to the legs and ground them smooth to match the contour of the legs/corners.
 

Vaughn McMillan

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Perfect project for powder-coating.
BTW, don't consult with Vaughn - he'd insist on purple! :rofl:
Well, Darren would be the only guy on his block with a purple CNC machine. So there's that. :D

Lilac and White trim

Whats wrong with a metal flake purple?
Now you're talking. Purple metal flake, with gray ghost flames. :thumb:
 

Darren Wright

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I think I've made about 10 lbs of chips with this project. These are the side plates for the cross members on the front and back. Each have 3 holes. Each hole was drilled out with an 1/8" bit, then a little over 1/4", then to a little over 3/8". I had to do the same for each of the legs, but by hand after transfer punching these to each. Each leg had 6 holes, 3 on opposite sides for through bolts.
2020-03-29 14.40.33.jpg

So I got the front and back cross members tack welded up today with a gusset on each.
2020-03-29 17.19.56.jpg
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I ran out of time to get to the borg for bolts, but found 4 in the bolt bin of the right length to mock up the table.
2020-03-29 19.23.49.jpg

The sides of the table are about 40" tall, overall we'll be over 67" tall to the top of the gantry motor.
2020-03-29 19.25.46.jpg

Here is the table mocked up without the gantry.
2020-03-29 19.23.33.jpg
2020-03-29 19.28.56.jpg

I have enough material to finish up the middle cross members, but will need to pickup the square tubing for the raised table yet. I'll get some more bolts tomorrow along with everything else I think I may need, then may trak out to pickup the remainer of the steel later this week if the metal shop is still open.
 

Darren Wright

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Gonna have casters for positioning? That is going to be a real heavy weight.
I could add some threaded ones, but I plan to have it as a stationary machine. Once I finish all the welding I'll disassemble it and re-assemble in the area it will live. My shop floor is just too un-even for it to be moved around much and keep the bed level.
 

Darren Wright

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Nothing too exciting today, I ran and grabbed some bolts put them on somewhat loose.
20200330_181120.jpg

Then I leveled it side to side, front to back, and corner to corner, then snugged them up and doubled checked all again.
20200330_181451.jpg

One of my leveling bolts was froze up, so will have to cut it off and replace it, but shimmed it for now

My measurements are dead on, side to side, for mounting the gantry. I will do all the final welding with it bolted up and leveled before installing and finishing up the gantry.
 

Darren Wright

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Today I got some end caps welded on the rectangular tubing for the table ends and got most of of the welds ground down. I need to disassemble it to get a few that are left. I got some new welding tips for the welder, it's working much better.
2020-04-04 14.33.13.jpg 2020-04-04 14.33.20.jpg
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I also cut some plates to bolt on for the cross members, those need to be drilled and bolted on, then I'll weld them up in place tomorrow. I'll then get it broke down and finish up some of the grinds, go over it all with some flap discs, and start painting them.

BTW....Looks like the paint scheme will start with black, since I have several rattle cans of it on hand. ;)
 

Darren Wright

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Tonight I got some more drilling done. The side plates for the cross members, which I then got tacked into place and welded up.
2020-04-06 18.09.25.jpg
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2020-04-06 18.09.14.jpg

I then finished up drilling the base pieces for the gantry. I need to weld on some end caps and grind them down, then I'll get them welded onto the gantry.
2020-04-06 21.25.16.jpg

Lastly I disassembled the table so I can finish up grinding/finishing and start painting.
2020-04-06 21.37.31.jpg
2020-04-06 21.37.41.jpg

I'll start moving the old cnc to out of it's area and also move my electrical and plumbing surplus to a new home in the shop, then will start reassembly there after paint is finished.
 

Darren Wright

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Any guess yet how much the new rig will weigh?
The steel comes in at about 300 lbs, and with the rails/screws (60lbs), motors (45lbs), spindle/z axis (40lbs), spoil board, etc, probably close to 450 - 500 lbs total.

BTW, I was originally planning to use 1/4" and 3/16" steel in 2x4" & 4x4" sizes, glad I refactored things a bit now.
 
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Vaughn McMillan

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The steel comes in at about 300 lbs, and with the rails/screws (60lbs), motors (45lbs), spindle/z axis (40lbs), spoil board, etc, probably close to 450 - 500 lbs total.

BTW, I was originally planning to use 1/4" and 3/16" steel in 2x4" & 4x4" sizes, glad I refactored things a bit now.
Hmm...I had kind of figured it was heftier than my lathe, but it looks like it's not quite as heavy. Still going to be a substantial piece of machinery, though. :thumb:
 

Darren Wright

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Did a lot of weld grinding, got all the table parts done, didn't have as much black paint as I thought, but was able to paint all the areas that I'll be mounting hardware on and together at, so will get more when I can and finish up the unpainted areas later. I also got the adjustable foot that was froze up cut off and replaced the nut. I've got some new floor levelers coming this week to replace the carriage bolts.
2020-04-07 19.16.01.jpg

I also welded caps over the gantry base ends and ground them down, then got them tacked up to the gantry. I'll finish up the final welds on it later this week.
2020-04-07 19.16.20.jpg
 

Darren Wright

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After the Happy Hour tonight I headed up and did some more painting
2020-04-08 21.36.24.jpg

Amazon also delivered the new adjustable feet today. Unfortunately I had another carriage bolt bind/snap taking it off. The galvanized carriage bolts are just too soft and the threads get gunked up. I'll have to cut that nut off tomorrow and weld another on, but the new feet work great on the 2 that came out and the one I welded on yesterday.
2020-04-08 19.59.54.jpg

While waiting on paint to dry I drilled and tapped the holes for the gantry ball screw and motor.
2020-04-08 21.36.33.jpg
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The distance to the shaft is going to be a little short, so I have a coupling and piece of shaft material to add to extend it out. I'll need to add a spacer or spacers between the gantry and motor to accommodate the additional coupling.
2020-04-08 21.38.41.jpg
 
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