Designing a new router called Brevis-HD

Hi Al - My first shot at a parametric isogrid. I usually do this in Rhino but then its hard to adjust, In fact every iteration has to be rebuilt entirely. That's why I should get into Grasshopper. The prior semicircular solution weighs 19.77kg and this weighs 11.95kg nearly half. It deflects 0.36mm vs the 0.12mm of our best so far, poor result. But its an attempt. The grillage should be behind the rails.but I couldn't figure out how to do that parametrically. I built this as two counter helixes and some longitudinals. I'll have another crack soon. My thoughts are I can have a tube laser cut with all the holes, but then I'm choosing the solution based on manufacture. I can 3D print nearly anything so shouldn't consider manufacture yet. Peter

this should be in the other thread

Hi All- I also did a semi circle in fibreglass. It weighs 11kg so same as steel isogrid. It deflects 0.23mm so is ahead of the isogrid but not as good as the steel semicircle. The FG section is 20mm thick. If I went to CF then it would be lighter and as good as the steel semicircle but 20mm of CF is costly. Easy enough to make the section bigger to get to the required deflection but then loose apples to apples on envelope.

Meant this for the other thread!!

Hi All - Picked up my truck yesterday and then the ply for the bench and resin for coating the bench. Now I can get serious at last. The trucks airflow sensor had failed causing the injectors to fill the cylinder with fuel and then fuel being incompressible caused the timing belt to jump a tooth, then everything is out in the control system so it wouldn't start. Took a bit to figure that out. But now its running and the valve timing was also done and its running better then its ever run... yeh Peter

Yeh - Finally some physical evidence of a build!! Started the bench today... Guess which bit it is?? I have been testing some water based epoxy and some vinyl ester resin as timber finishes. I think I'll go with the VE resin, cures very hard and is the cheapest as well. I use an infusion grade not laminating grade resin. This gets sucked up by the end grain and seals everything really well....Peter

Hi All - Today built the bench end to near complete. I'm doing the bench out of lightweight plywood. Its also modular Scoot was 40mm plywood top with 16mm MDF laminated cabinets and although could be broken down into 3 pieces was really heavy to move!! So This ones in 4 piece and the light ply makes each piece liftable. Std plys about 650kg/m3 this is 350kg/m3. Tomorrow make the other large end then start painting it. For those interested the benches are butt glued screwed then screws removed and dowelled.

Nice progress Pete, always encouraging to begin the stack up. Lower weight is a pain saver in the home shop environment.
All the best.

Hi Rube -Thanks got into the other side of the bench today. Hopefully will be able to prep the 3 bits for paint by end of day. Ignoring the phone! In the image that's Brevis-1 my smallest router in the background. YaG will be just under 1/2 sheet size. Then I shall use YaG to make a large router in composite.
Re: weight, yes a while ago I used to be able to cart sheets of ply around but now its an effort!! so manageable weights is always in my plans...Cheers Peter

Hi All - Busy today making the second cabinet and dowelling the bits. I started painting the middle cabinet red. I have some red paint handy. The bench top and bottom is formply. I'm going to paint the formply edges red as well for a bit of POP. The large cabinets will be varnished to contrast the dark formply. Maybe able to set up castors and levellers on bottom very soon. Keep Makin , Peter

Hi All - Today's job was to close out the cabinets. So next is to complete the dowelling then topcoat the red middle cabinet and start varnishing/clear coating the large cabinets. Wednesday I start fitting the castors and levellers so it will be a bench very soon. Peter

Hi All - I got the bench base made today, flipped set into place and leveled. Now to finish painting the cabinets and work towards full assembly next wednesday. Looking fwd to a gretra bench to build YaG on. The levelling castors worked nicely. Keep Makin Peter

Hi All - Today I pretty much finished the cabinets. A final coat tomorrow and then I assemble the bench on tuesday. Then I can get onto the machine base. Its the first time I have used a foam brush. Very impressed. Lays off very nice. Peter

Hi All - Finished the cabinets today. Put on the braces and decided which side was front and up. Saturday I screw the bench together and finish the top. Then YaG has somewhere to live. Peter

Hi All - Not much to show but the cabinets are done. The red is water based epoxy. It's a dipping paint that I was experimenting with for small parts. Mixed results on metal so used it on the cabinets accents. I also played with a foam brush, liked the results, it lays off very well. Very thin coat so if your happy to do many coats gives a great result. Used an acrylic sealer on some parts as I have not used that before. But mostly used dilute PVA white (1:1 water) glue as the sealer. This levels fast and allows knocking the grain down fast. The clear timber is again white PVA used as a varnish. About 6 coats gets just past level (or some call choked). Next time I will use a semi finished ply or a textured birch to save some time. The cabinets have room for a vacuum system and a tool drawer plus all the other stuff. The bench base and top are 25mm formply. Next bench I'll break out the spray gun!

Its been a little practice run for YaGs machine base. Will review base parts and get them ordered quick sticks....The cabinets came out quite square and true so very happy with that...will make more clamping squares they really helped...Don't think I'll dowell again. Will use glue & screws, remove screws, paint and replace screws. Cost the same but saves time. Use square drive screws so they look good. cheers Peter

some granite porn for those into machinery & stonework. Peter

https://www.youtube.com/watch?v=xdaqsS1HE-o

Evening All - Today I made some upstands for the bench as it is too low!! Not sure what I was thinking when I designed it but easy to fix. I had also considered the height of the machine base so must have set that a bit low as well. Anyhow I made the stands, relevelled the plinth then set up the cabinets and screwed then down. I rounded the corners of the top and checked it was level and square and started painting the edges. The edges have blackish paint already and its clear the red won't cover that. So I'll plane it back to timber and paint. So now onto the machine! Excellent. Peter

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Originally Posted by peteeng

Evening All - Today I made some upstands for the bench as it is too low!! Not sure what I was thinking when I designed it but easy to fix. I had also considered the height of the machine base so must have set that a bit low as well. Anyhow I made the stands, relevelled the plinth then set up the cabinets and screwed then down. I rounded the corners of the top and checked it was level and square and started painting the edges. The edges have blackish paint already and its clear the red won't cover that. So I'll plane it back to timber and paint. So now onto the machine! Excellent. Peter

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How high is the Table from the floor it really all depends how tail you are, sometimes a low table is good

Morning Martec et al - The bench design height is 700mm high (This is less then sitting desk height) This makes the machine bolster height ~900mm which is good. I made the bench upstands 80mm high as this was some square stock laying around. I'll set up the machine base at minimum height on the levellers (US levelers) and I think it will all work out. Once everything is running I'll reassess the bench and remake if I have to. Will make a good assembly bench in the new workshop. The piers get laid this week. Regards Peter

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Originally Posted by peteeng

Hi All - I have a little project with a hiking trailer I'm making. The belt (towbar) needed stiffening so I made a little stiffener for it from some scrap carbon fibre on Brevis-1. Now I paint it red because I have red epoxy paint in stock....

The trailer is in its 3rd iteration and quite mature. The belt is in its 4th design and now I'm happy with the lot. Need some diversion therapy sometimes....

https://www.facebook.com/ScootCNC/vi...2712453431441/ Peter

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do you use a pony on that cart?:rolleyes:

Hi All - Tomorrow I screw the benchtop onto the bench properly then start sorting and repacking it with my tools and materials. Then it's onto the YaG machine base proper. We laid the piers for the workshop yesterday so now we can start going up rather then down. Been playing with the transient dynamic solver in simsolid. Getting the hang of setting up dynamic models.

Transient means the solver figures out how the structure behaves over time say 10 sec or 20 sec or more. I can also set the structure dampness so parts of it will wobble but these diminish in time. Dynamic means the force can be applied over a time such as an impulse or in the routers case a constant force over time and distance. This means the resulting velocity and accelerations can be looked at as well. Its a little difficult to interpret some of the output.... So I talked to the supplier and I'm trying to do things the software can't quite do so I'm upgrading the SW so the structures will slide along the rails correctly... hopefully get the upgrade next week... Peter

MORNING All - On the weekend I got the benchtop levelled and tight so now I have a flat surface to start YaG on. Sorted all the prior materials and tools and put them on shelves. Now I'll get the plastic crates and trays sorted and bought for the shelves. Had a hiccup with my vacuum pumps resin trap. Its too big for any of the shelves so I'll have to make a smaller one. It's designed for trapping large quantities of resin when building boats so a bit of overkill in this application anyway. Will get a water filter I think. Sawdust is the real issue in this application.... time to pull down the pump and give it a cleanup anyway and some new oil... one more thing on the TODO list. I also got the edges painted so it's pretty close to finished... is anything ever "finished"?

Question for all you out there. I'm looking for economical laser measuring and levelling tools (or ultrasonic or other method) for setting up machines. I currently use normal levels and a machinist level but want to go a bit better than this if possible? Any leads? Regards Peter

The bench is at the local Mens Shed that I'm a member of. When I get the workshop built I'll build a big machine. The shed is making a new propane forge which will be interesting. The conventional charcoal one we have is a bit fiddly. Some of the bits are in the photo. I help some of the guys make knives occasionally. They have to get their temps right and steel grades right for various things... Keep Making