Making the Machined Parts.

Base and X axis Motor mount & End Bearing Mount Riser Blocks X axis nut plate assembly Y axis nut plate assembly X and Y axis Bearing Blocks

Z axis assembly
Main vertical plate Slide assembly Z axis back plate Z axis Slide Assembly Z axis bearing blocks Z axis nut plate Z axis Motor Mount Top Base Top corner blocks X axis Proximity Switch Bracket Router Motor Mounts Makita Router Bracket Bosch Router Bracket Porter Cable Router Bracket

This document details the parts that need to be machined. Most of the parts are now available already machined. Each part is listed with the material needed to make the part and the cost of the machined part.

Motor Mount & End Bearing Mount

The motor mounts and end bearing mounts are made from a 4 square aluminum extrusion cut to a 4 length with a wall thickness of 1/4. The drawing on the right shows how three sides of the motor mount would look if it they were unfolded. The fourth side is blank. The End Bearing Mount is the same as the motor mount without the hole for the motor mount. The next three pages describe the details for machining the motor mounts and end bearing mounts. Mark one of the open ends as the top and do all your measuring from that end. Using your templates is a good way of keeping all the holes properly centered. Care must be taken to make sure that bearing block holes on each pair align up properly. The pre machined parts are sold as pairs.

Motor Mount Motor Side

Machining of the center hole is best done on a drill press or a machining center. There are various types of fly cutters and hole cutters available to cut the hole. Some extrusions will not be exactly 4. mark a vertical line between the open ends that is exactly in the center.. Attach your template making sure that one side is flush with the open end that you have marked as the top side. Now make sure that you can see the vertical center line through the center hole in the template. Tape the template to the extrusion. At this point, I use a 1/8 drill bit and drill a starter hole through the templates. Once you have the centers marked, you can use a fly cutter on a drill press or a hole saw on a drill press to cut out the center hole for the stepper motor. The mounting holes for the stepper motors are drilled and tapped for 10-32 socket head screws.

Price per pair $60.00. Quantity needed: 2 (X and Y axis.)

Motor Mount Mounting Hole Side

Some extrusions will not be exactly 4. mark a vertical line between the open ends that is exactly in the center.. Attach your template making sure that one side is flush with the open end that you have marked as the top side. Now make sure that you can see the vertical center line through the center hole in the template. Tape the template to the extrusion. At this point, I use a 1/8 drill bit and drill a starter hole through the templates. The four mounting holes are drilled for 5/16 The holes are centered on 1.5 spacings.

Motor Mount Bearing Side

Some extrusions will not be exactly 4. mark a vertical line between the open ends that is exactly in the center.. Attach your template making sure that one side is flush with the open end that you have marked as the top side. Now make sure that you can see the vertical center line through the center hole in the template. Tape the template to the extrusion. At this point, I use a 1/8 drill bit and drill a starter hole through the templates. Once you have the centers marked, you can use a fly cutter on a drill press or a hole saw on a drill press to cut out the center hole for the bearing block. The mounting holes are drilled and tapped for 10-32 socket head screws.

Riser Block top and Bottom

Material: 6061 aluminum 3/8 thick. Four required. There are four riser blocks (two on each side). One is designed as 7 tall and the other is 9 tall. At one end of both blocks you will install a top/bottom riser block. Drill 12 5/16 holes. The holes are on 1.5 centers. Countersink the middle four holes with an 82 deg. Countersink for a 5/16 flathead screw. The plates are then screwed to the ends of the four riser blocks with 1 or 1.5 flat head 5/16-18 screws. Note: The bottom plate can be made the same length as the mid as shown in the picture above. The top plate is oriented in the same direction as the bridge.

Machined price $15.00 each. Quantity required: 4.

Mid Riser Block Plate

The material is 3/8 or 1/4 6061 aluminum. Four required. All holes are on 1.5 centers. The four center holes are drilled for 5/16 and countersunk. These holes will mate up with the 3 by 3 extrusions. On two of the plates, the outer four holes will be drilled for 5/16. The other two plates will be drilled and tapped for 5/16-18 button head screws.

Price per pair: $22.00 Quantity required: 2 pair

X axis Nut Plate Assembly Side Plates

The X axis nut plate assembly is made from three pieces. Two side plates and one center cross piece that the flange is attached to. The side pieces can be made from 1/4 6061 or 1/8 6061.. The cross piece is made from 3/4 6061. The picture on the right shows the side plate made from 1/8 6061.

Material 6061 aluminum. 2 required. The horizontal spacing for the three holes at the top is not critical. The three holes will be drilled for 5/16 screws. The two vertical screw slots are machined for 1/4 screws.

Price per pair: $22.00

X axis Nut Plate Assembly Cross Plate (3/4 screw flange)

2 1
Material 3/4 6061 aluminum. This picture shows the center plate drilled for the 3/4 screw flange. The center hole is drilled all the way through and needs to be large enough for the 3/4 screw. The four mounting holes are drilled and tapped for 1/4-20 screws. The mounting holes at the ends are drilled and tapped for 1/4-20 screws.

Price: $17.00

X axis Nut Plate Assembly Side Plate X axis Nut Plate Assembly Cross Plate (5/8 screw flange)

1.688 1

Material 1/2 6061 aluminum. This picture shows the center plate drilled for the 5/8 screw flange. The center hole is drilled all the way through and needs to be large enough for the 5/8 screw. The four mounting holes are drilled and tapped for 10-32 screws. The mounting holes at the ends are drilled and tapped for 1/4-20 screws.

Price: $17.00

Y Axis Vertical Nut Plate

Material: 3/4 6061 aluminum. To the right are two Y axis nut plates. One for the 3/4 screw and the other for the 5/8 screw. The three holes for the flange on the right are drilled and tapped for 10-32 screws. The four holes for the flange on the right are drilled and tapped for 1/4-20 screws. The top three edge holes are drilled and tapped for 1/4-20 socket head screws. This part will mate with the Y axis back plate.

Price: $17.00

Bearing Block

Material 1 by 2 6061 aluminum. Four required The center hole is machined for a 7/8 OD bearing. The four mounting holes are drilled for 10-32 socket head screws.

0.2929 1.57

0.2

0.2929 0.875

1.4142

0.5

Price: $17.00

Z Axis Assembly
To the right is a picture of the Z axis vertical assembly. You will need to identify several of the items that make up the Z axis assembly. Stepper motor Flexible coupler Bearing block

Bearing rail
Proximity detector

Lead screw nut

Lead screw nut plate

Slide assembly

Z Axis Vertical Support Plate

Material 3/4 6061 aluminum. Now you can prepare to make the Z axis vertical plate. First find your template. Tape the template to a piece of 3/4 thick 6061 aluminum 17.25 by 8. Mark all the drilling holes with a 1/8 drill.

2.1563

1.5 2.3622

4.75

3
Basically you will have two hole sizes. 10-32 tapped holes for the HIWIN 20mm rails. 1/4-20 tapped holes for the bearing blocks. NOTE: If you use 15mm rails, The holes will be drilled for 6-32 socket head screws. The center group of holes are drilled and counterbored for 1/4-20 socket head screws to attach the back plates. NOTE: If your flexible coupler is greater that 1 in diameter, you will need to pocket out an area just above the top bearing to accommodate the coupler. The seven vertical holes in tow columns are for the HIWIN rails. They should be on 60mm centers. Drill and tap the holes for 10-32 screws.

17.25

2.205 2.295 1.2598

0.6025

The two holes at the bottom with 1.5 spacing are for the bearing blocks. They should be drilled and tapped for 1/4-20 socket head screws. Do the same for the two holes at the top. The one hole 4.25 down is for the proximity switch. This hole needs to be drilled and tapped for 12mm by 1mm.. Price: $80.00

1.2598 0.9063

Z axis Back Plate

8.1711 2.7207 1.2598 0.82 8 1.25 4 1.2598 2.205 1.85 1.4275

0.75

2.295

2.295

0.6693

Material 3/4 6061 aluminum. The eight mounting holes for the HIWIN bearing blocks are drilled and counter bored for 5mm socket head screws. The single large hole is for mounting the Y axis proximity sensor. Drill and tap this hole for 12mm by 1mm . The four edge holes are drilled and tapped for 1/4-20 screws. NOTE: The mounting holes are for 20mm HIWIN bearings. If you are using THK or IKO bearings their may be a slight difference. Contact bob@campbelldesigns for any updates for THK or IKO bearings. The three holes on the left side are drilled and counterbored for 1/4-20 socket head screws. They attach to the top of the Y axis nut plate Price: $20.00

Z Axis Slide Assembly Side 1

This drawing is only for the 20 MM Hiwin rails and bearings

Material: 6061 aluminum 3/4 thick. NOTE: This drawing shows holes for the four hole HIWIN 20 mm bearing blocks. The bearing blocks are centered on the line of five holes that are five inches apart. The 16 bearing holes are drilled and counterbore for 5mm socket head screws. The two vertical columns of five holes five inches apart are drilled and tapped for 5/16-18 screws. The slide unit will need to be machined on the reverse side to clear the lower lead screw bearing block.

Price: $25.00

Z Axis Slide Assembly Side 1

This drawing is only for the 15 MM THK rails and bearings

Material: 6061 aluminum 3/4 thick. NOTE: This drawing shows holes for the four hole THK 15 mm bearing blocks. The bearing blocks are centered on the line of five holes that are five inches apart. The 16 bearing holes are drilled and counterbore for 5mm socket head screws. The two vertical columns of five holes five inches apart are drilled and tapped for 5/16-18 screws. The slide unit will need to be machined on the reverse side to clear the lower lead screw bearing block.

Price: $25.00

Z Axis Slide Assembly Side 2

This reverse side needs to have an area shown machined to a depth of 3/8 to clear the lower lead screw bearing block.

Z Axis Bearing Block

Material: .75 thick 6061 aluminum. Two required. The bolt holes are for 1/4 socket head bolts and are counter boarded. The center hole is for a 7/8 OD bearing. Each block requires two bearings.

0.257 0.413

0.35

0.8875 0.257

Price: $15.00 2 required

Z Axis Nut Plate

Material: 1/2 thick 6061 Aluminum. The center hole is drilled and tapped for 15/16-16. This will match the threads on the lead screw (BS&A) nut.

0.375

0.9063

0.875

Price: $15.00

Z Axis Motor Mount

4
Material: 3/4 thick 6061 aluminum. The inner 1.5: hole is machined all the way through. The larger hole is pocketed down .1. The mounting holes for the stepper motor are drilled and tapped for 1032 socket head screws. The bottom of the edge near the large mounting holes (dashed line)will need to be relieved about 1/6 in order to slide the back cover in place. The other two holes are drilled for 1/4-20 socket head screws.

2.74 4.5 1.5

6 2.9

Price: $17.00

Base Corner Plate

4 0.75 1.002 4
Material 3/8 6061 aluminum. Four required. This is the base corner plate for the table top. This plate is designed for the HIWIN 20mm rails and bearings. The holes for the HIWIN bearings are drilled for 5mm. The other three holes are drilled for 5/16. If you are using THK or IKO bearings, the hole spacings for the bearings may be different.

1.2598

1.0433 1.2598

0.75 0.75

Price: $6.00 each 4 required

X Axis Proximity Switch Bracket

Material: 1/4 thick 2 by 2 6061 angle material. The two side holes are drilled for 5/16 screws. The single hole is drilled and tapped for 12mm.

0.875

0.75 0.75
Price: $10.00

Router back plate

0.5 2

4.25 6.5
Material: 3/4 6061 aluminum. This is the backplate that the router bracket is attached to. The two holes at the bottom are drilled for 3/8 flat head screws. Both holes are countersunk. The other four holes are drilled for 5/16 screws. Price: $23.00

Bosch Router Bracket

Material: 1.5 thick 6061 aluminum or a plastic like UHMW. If you use a plastic material, the thickness can be as much as 2. The pair of holes at the bottom is drilled and tapped for 3/8. This part mates with the vertical plate that has been drilled and counter sunk.. The other pair of holes in the bottom half are drilled and tapped for 5/16 socket head bolts. Price: $30.00 Made from UHMW

Porter Cable Router Bracket

Material: 1.5 thick 6061 aluminum or a plastic like UHMW. If you use a plastic material, the thickness can be as much as 2. The pair of holes at the bottom is drilled and tapped for 3/8. This part mates with the vertical plate that has been drilled and counter sunk.. The other pair of holes in the bottom half are drilled and tapped for 5/16 socket head bolts. NOTE: If you are using plastic and you think that the top and bottom edges are too thin, you can change the edge dimensions. Price: $30.00 Made from UHMW