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Scratch Build – Complete Project QUAD - a Quick and Dirty PC/Spindle cooling with CNC Router attachment

Discussion in 'Project Logs' started by dan297, 7 May 2021.

  1. dan297

    dan297 Modder

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    Started with the X-axis today.
    First off, after assembling the rails and carriers, I had to mount the front and back plate.

    20210703_102504.jpg


    It is good that I refrained from adding immeadiately the threads and through holes to the angled brackets.
    The dimensions are rather odd with 25.75mm from the edge...

    20210703_123556.jpg


    The longer brackets sit a little bit tight with the fixed bearing block of the BS, but still ok.

    20210703_133249.jpg


    Next came the mounting blocks for the feet.
    Believe it or not, those were not included, but an option...for 89 EUR :eeek::eeek::eeek:
    Too expensive for my taste, so I made my own ones...

    20210703_151813.jpg


    Unfortunately, the feet are not there yet :wallbash:

    20210703_152505.jpg
     
    Last edited: 3 Jul 2021
  2. dan297

    dan297 Modder

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    The rest of the afternoon I fiddled around with the end stop.
    The kit is equipped with mechanical reference switches, but I prefer inductive proximity switches.
    They are simply more precise and repeatable.

    The downside is I have to make two extra blocks. One in aluminium for mounting the switch and one in steel as an actuator.
    But since the table/bed is aluminum they are easy to fit. Just some drilling and tapping.

    20210703_170042.jpg


    Two countersunk holes in the cross bracket...

    20210703_184327.jpg


    Rigid tapping of small threads in steel always gives me the creeps (and sometimes a new dowel pin :grin:)

    20210703_190107.jpg


    Measurement and aligment of the actuator block in reference to the sensor took some time, because they are located on two different parts and I definately wanted to avoid operator brainlock...:lol:

    20210703_190811.jpg


    The fine tuning I can do with the threaded sensor...

    This part of the design I actually like a lot. This cross bracket under the bed connects the two sides of the portal.
    So the portal is not just a C-shape, with two side plates and the cross plate with the rails, but a full rectangle.
    This should improve lateral stiffness a lot :thumb:

    20210703_191335.jpg
     
    Last edited: 4 Jul 2021
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  3. kim

    kim hardware addict

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    I assume it will come out some amazing projects, from this amazing tooling :naughty:
     
  4. dan297

    dan297 Modder

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    I hope so, mate :thumb:
     
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  5. dan297

    dan297 Modder

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    I disassembled the rear plate again, because I forgot two features.
    Two M4 threads for a small box, to which the 3D-probe and tool length probe connect.
    And a bulkhead connector for the BS nut greasing.

    And while I took a closer look at the plate, I noticed that the threads for the servo mounting are M4, not M5.
    So that was the first thing to change. They probably did that, because the two upper threads are really really close to the edge, was 1mm, now just 0.5mm.
    Have to take it easy with the tightening torque...

    20210704_093303.jpg
     
    Last edited: 4 Jul 2021
  6. dan297

    dan297 Modder

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    There is no way that I ever lift this +100kg thing in order to grease the X-axis BS nut.
    So I added this bulkhead fitting for a remote access.

    20210704_111133.jpg


    Now I can just press grease in that fitting and I shall be fine. The tube is already filled with grease, so I do not have to push too much air through the BS nut at the first maintenance...

    20210704_111125.jpg
     
    Last edited: 4 Jul 2021
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  7. dan297

    dan297 Modder

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    Next came a few modifications of the two gantry sides.

    Two additional M8 threads for the extended brackets.

    20210704_124033.jpg


    I also drilled out the rear countersunk holes.
    For whatever reason why they put an M5 thread instead of a Ø5.4mm hole in those two countersunks.
    In the assy instruction they are not used anyway. The rear carrier is supposed to fit to the 4 countersunk holes in the middle.
    But I decided to move it back and use the rear four holes. I loose 36mm in X travel this way, but in order to counter any bending forces in this direction I feel a wider base is useful.

    One of the sides have a recess to get cleareance for the servo. Since I will flip the entire portal 180 degrees, I had to mill the same recess as well into the other side...

    20210704_150606.jpg


    During assy the sides rest on the carriers on these two dowel pins. They will be removed once the screws are tightend...

    20210704_152100.jpg
     
    Last edited: 16 Jan 2022
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  8. dan297

    dan297 Modder

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    Next I dealt with a design feature that I really dislike in this router - only 3 carriers on the Y-axis. Same on the Z-axis, but that has already been taken care of with my own Z-axis design.
    The top rail is shorter by 60mm. In order to use as well two carriers on the top I had already ordered a rail, which has the same length than the bottom one, but I needed to mill the aluminium profile accordingly.

    20210704_160450.jpg


    While I did that I noticed that the profiles are not flush with the portal :duh:

    20210704_160848.jpg

    It is minimal, but inconsistent. One is flush, the other is not, same at the other end...
    The end plates, which go on top of that, have no real function, so probably no big deal, but I disliked it anyway...

    Time to make some use of the biggest endmill in the shop :grin:

    20210704_161123.jpg


    Much better now :thumb:

    20210704_162958.jpg
     
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  9. dan297

    dan297 Modder

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    The rest of the afternoon I spend with aligning the gantry and the X-axis BS.

    Starting to look like a router :grin:

    20210704_200836.jpg
     
    Last edited: 16 Jan 2022
  10. Cheapskate

    Cheapskate Insane? or just stupid?

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    Surfaced parts, countersinks, double sided milling operations, milled table... I'm betting this thing was expensive.
    Edit: Just looked it up. :worried:
     
    Last edited: 5 Jul 2021
  11. dan297

    dan297 Modder

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    Pricey, yes.
    Expensive? I find that is relative to what you get.
    Their machining is without a doubt top notch. The cross bracket of the gantry sits so snug, almost a press fit. And this part has an integral role in the alignment/accuracy of the portal.
    Also the gantry sides (where the portal beam rests on) are pretty darn accurate.

    For the pre-alignment I mounted the carriers and the cross plate and fitted a lever dial indicator.
    I clamped a precision square to the table slots and measured the difference left to right in Z and Y.
    And believe it or not - I was done in less than 5 minutes. The indicator has a resolution of 0.01mm and I measured 0.02mm in Z and 0.03mm in Y over a distance of 400mm (the length of my square)
    The fine tuning (with aluminum foil) will be done once the servos are hooked up, to avoid any impact from me pushing against the gantry.
    Yes..it is still a gantry and you can flex it by hand...

    But the out of the box accuracy just after assy really surprised me. I did not expect that. :thumb:

    In their non-professional line-up they have 4 different models, and each model comes as well in different sizes.
    Rather basic ones, which you can just use for wood up to really sturdy ones for multi material work.
    They differ in stiffness, linear guide types, screw types, etc...

    I went with their second best model, mainly because I liked the concept with the integrated table.
    When you compare router prices, this is often overlooked.
    If you just do wood, a less expensive frame type router is perfectly fine. You put a plywood board on top and face it off. Add a few holes for clamping and you are good to go.
    But for milling aluminum, clamping a vise to the bed, etc... something more rigid is required.
    And a precision milled 800x500x20mm slotted aluminum router table alone is already north of 400 EUR :eeek:

    I compared several different routers in the 3000 EUR class (Heyder, Stepcraft, BZT, etc...) and I could not find a single one, which I liked right away.
    This one is essentually the one I disliked the least :lol:

    There are a few design features, like the integrated table and the gantry cross bracket (stiffness), the beam extending the gantry sides (full use of the table in Y) and the overall modularity, which are real advantages.
    But there are as well many things not so great in this design, like the original Z-axis, or the 3 carrier design on the Y-axis.
    Those negative points I try to fix one by one right now, hoping to end up with a machine, which will last until I am too old to work with it (20 years...:eeek:)

    That is the lesson learnt from my early days, when I compared and bought tooling just by price (because I was unsure if I stay with the hobby and could not afford decent tooling anyway these days...)
    All of this stuff has already been replaced, either because it died on me, or because of the poor results it generated (or was that me???)
    If you buy cheap, you buy twice.
    And that is perfectly fine, when we talk hand held tools in the +/-100 EUR range. Start with affordable stuff and graduate to better quality some years later, when you are sure this is your thing.

    But stuff beyond 1000 EUR I prefer to buy only once in a lifetime. And I'd rather save up 2, 3, 5 years until I can afford it (within reason), than to go mad about a shitty purchase in this price category...
    Unfortunately, I have to work too hard for the buck I can spend... :wallbash:
     
    Last edited: 16 Jan 2022
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  12. dan297

    dan297 Modder

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    I made some progress these days, finished the Y-Axis cross plate. Nothing fancy.

    Some tapping...

    20210707_122702.jpg


    Some drilling and counter boring...

    20210707_133854.jpg


    Done!

    20210707_154849.jpg
     
  13. dan297

    dan297 Modder

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    That was the last DIY part missing.

    I needed a new one, because I flipped the Y-axis beam, so that the fixed end of the BS (and the servo) is on the other side of the portal.
    I did that, because all the wires and tubes from the Z-axis were supposed to run between the top of the beam (where they exit the drag chain) and the servo.
    That works fine with an air cooled regular spindle with just one power line. But with all the air hoses and water cooling tubes of the ATC spindle the bundle is too thick for that.
    Now that the servo sits on the other side there is enough room for that.

    The beam is not symetrical, so the holes in the plate need to be rotated as well.
    And I also use 4 carriers instead of only 3, so a completely new pattern was required anyway.
    Since I had to make a new one, I beefed the thickness up from 10mm to 15mm.

    A first preliminary test fit...

    20210707_173145.jpg
     
  14. Cheapskate

    Cheapskate Insane? or just stupid?

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    At some point, you passed over overly beefy. Those poor bearings on the Y.
     
  15. dan297

    dan297 Modder

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    They have to deal only with half of what the bearings on X have to deal with, since they move the entire gantry, not just the Z-axis.

    But I am not concerned at all about the axial forces for those angular contact bearings.
    This thing is still just a toy for them...:baby:
     
    Last edited: 16 Jan 2022
  16. dan297

    dan297 Modder

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    Did I say the last part to be made...?
    Not entirely true.

    Since I am using bigger drag chains than the ones in the kit, I had to make a new holder for the one on the X-axis.
    No appropriate stock at hand, so some round stock have to do again.

    First facing, then roughing and finishing...

    20210709_133829.jpg


    Then sawing.
    The part is 30mm wide and I milled 34mm deep, to have some leeway for an unclean cut...

    20210709_135453.jpg


    Facing the other side to size...

    20210709_104157.jpg


    At last drilling, tapping and counterboring.
    That was a bit tricky with the long endmill. I did that with the quill and very shallow cuts.

    20210709_155602.jpg


    I addad a few chamfers on the disk grinder and that was basically all...if I hadn't milled the first one only 20mm wide :wallbash::wallbash::wallbash:

    20210709_160106.jpg


    So far so good...

    20210709_163300.jpg
     
    Last edited: 16 Jan 2022
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  17. dan297

    dan297 Modder

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    More stuff came in today... :eeek::grin:

    20210709_093531.jpg
     
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  18. Cheapskate

    Cheapskate Insane? or just stupid?

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    Wouldn't it be better to have all the cables on the back side out of your way?
    Last pic: "No Mr. Postman! Not on the rug!" Bad Postman!"
     
  19. dan297

    dan297 Modder

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    Yeah, I debated this too.
    But once this is in the enclosure, the accessibility to the back side is rather poor.
    In case I have to change something...or clean chips.
    Since all cables will be in the drag chain, it should be a fairly clean setup...
     
  20. dan297

    dan297 Modder

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    Finally, some more progress.
    I went to my local metal dealer these days to get a few profiles.
    And I was pleasantly surprised that they dragged the off-cut bins right to the entry of the warehouse, so you can browse them again - without entering the actual shop :thumb::thumb::thumb:

    I could find all the profiles I needed as off-cuts, at a 15% discount :happy:
    The downside is...I also found some off-cut AW-2017 stock in those bins, which I couldn't resist buying :grin::grin:

    But it is good to see, they are almost back to normal...

    20210714_105704.jpg
     
    Last edited: 16 Jan 2022

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