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A few things I see.

I don't see any reason to machine anything out of the large side extrusions, more mass = better.

I would consider moving the ballscrews to the outside, there they will be...

That's kinda funny. I've been toying around the idea of making a coffee table with that very same data.

30 x 23.5 x 2.25 size. Thinking a plywood for the layers to look like topo lines, the 25...

I e-mailed Diane and got the following response for accuracy "Typical tooth to tooth error is .0010” with a total composite of .0019.” I have not figured out yet how to translate this into something...

Hmm, I purchased my rack gear from McMaster in January 2011, which was back when cncrouterparts had a link to McMaster for rack gear. I just checked McMaster again and didn't see any sort of...

My machine has ~1500mm travel in x and y, I currently am using McMaster rack gears. The tooth to tooth tolerances is unacceptable for doing any jobs for people. It would be easiest to replace the...

I have a rack and pinion drive on my setup. Even though I can achieve 1,000 ipm I regret using rack and pinion due to its lack in accuracy. Typical pinion gears don't come in a precision ground form...

Haven't posted anything in a while. Life has a funny way of bogging you down sometimes.

Finished my design, ordered my materials, manufactured my parts, assembled parts, built machine, working out...

@ger21:
I messed up my numbers, used 1/2" ballscrew data and curves. Have edited my above post, screw whipping doesn't appear to be an issue at this length.

Edit to add:
Will rotating the screws...

I purchased some inductive prox sensors off ebay and got them in yesterday (here, Inductive Proximity Sensor Detection Switch NPN 4mm DC6-36V LJ12A3-4-Z/BX).

I measured a 10k ohm internal...

I've been really worried about the unkown accuracy class, and lack of rigidity due to windup of the rack and pinion drive and have been searching around for ballscrews, chinese ballscrews to be more...

The 1/4" plate on the gantry face is primarily for what you said in the second part there. I intended for it to be an intermediate between the rail and extrusion to normalize stresses between the...

Good points about the Z-plate, simple beam calculations show .009" deflection under what I expect max tool load. I may add a rib to the outside edges, some aluminum bolted in down the sides. However,...

Here is something I got in today that seems to have potential.

Shop fox D3347 cam clamps. $10.35 on amazon. HERE

http://ecx.images-amazon.com/images/I/31Ap3YbJm7L._SL500_AA300_.jpg

Seem to...

The current 4'x4' cnc router I have now works well but its accuracy, precision, and stiffness are lacking to my expectations. In the last several months I have had to turn down some well paying jobs...

I really like your horseshoe design on post #129. Would it be possible to get the .crv file for that for vcarve? Bought vcarve some time ago and I am still much a newbie at the program.

Also, what...

Over the years browsing these forums I find there are many different machines of many forms, fits, and functions. Some of the things that make the best machines though are the extra's.

What I...

The 1200mm lengths aren't long enough for what I am wanting. My thoughts are to now order 6 complete sets, cut 2 for the Z axis, and butt together extra segments to the x,y axis to get the 1500mm or...

Not worried about spending the extra $$ as long as it is the right choice. My worry is greatly overspending when it isn't warranted.

On typical 4'x4' machines can one get away with only 1 rail on...

While I do like the Hiwin Rails and their gothic arch design allowing loading in any direction. I am a little frightened by a couple things:

Automatioin Overstock carries a discontinued product....

I understand a lot of the stackups and am taking them into consideration in my redesign. My original requirements may have to be widened but there is very little load on the machine during slow...

Need some help,

Rebuilding my 4'x4' router that I designed a few years ago, currently uses a cncrp bearing truck design. I am not too fond of this system as I have to fight the setup of the trucks...

My favorite:
Put all clamps in place align part and start program without actually tightening any clamp. walk away to do something (never made any scary sounds) come back a minute later to see very...

backlash isn't a problem at all. backlash refers typically to the "slop" or amount of play before engaging the coupler when reversing direction. Windup is how much the coupler deflects under load....

Shaft misalignment will overload bearings, ruin motors, and reduce torque delivery due to it fighting the misalignment. Coupling capable of parallel misalignment should be used when trying to deliver...

Helical couplers aren't the best choice for cnc. look into buying something like an oldham coupler.

McMaster-Carr.

Buy 2 hubs and one disk, that makes a complete coupler. Higher torsional...

using an m12vc router. with a 1.75" bit i think it would take a bit more horsepower than I have and also likely lower rpm then what it is capable of.

I am hoping I can fixture this correctly to...

sorry i should of provided more info, these are 1.75" diameter holes in 1/2" HPDE. 21 holes per sheet. 29 sheets to do lol.

Pocketing the whole feature would make an extremely large mess and also...

in the final pass sometimes the cutting force breaks the slug out before finishing the pass. The bit then hits the free slug and bounces it causing it to lift sideways and thus binding in the hole...

Gotta cut a bunch of holes in a bunch of boards for holders. I raise the boards off the table to allow the round scrap piece fall without interfering with the rotating bit.
...

oh yea, with 0.001" accuracy or +-0.0005", don't forget thermal expansion! which occurs after a machine runs for any amount of time.