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I just built a router with a design similar to yours, it is posted in the classifieds, I just don't have the time or money to finish it, it all seems super solid, the design looks nearly identical,...

Those onsrud bits look nice, but they are super expensive. Check out www.duramill.com, there aluminum cutters work great, but are less than $30 for a 1/4 inch coated cutter, where it looked like...

Well, I started after finding the zone, but I had the idea before finding it, that is how I found it, I was looking for info on cnc routers etc. I have found tons of usefull info and am glad that...

Oh, I plan on using the milwaukee 3.5 horsepower router, so my gantry completly assembled will be kind of heavy. Any recomendations on motors, even if it isn't one of the above ones that I was...

You definatly ned a carbide cutter. I have had good luck with the duramill carbide aluminum cutters in 1/4 inch. I spin the router at about 16000 rpm, and use a-1 for cutting fluid. Just play a...

Here are some more pics, mostly of the fram advancements. I will have steel legs on this, because I don't want to order more 8020, and I can get steel easily. The reason I went with the 8020 is...

alright, here are some more pics. I got my ballscrew assemblies pretty much done, and I have ordered my couplings from mcmaster carr. I still don't have any of the electrical stuff, I am deciding...

Sweet, thanks for all of the replies. I was definatly thinking about getting the mk 5625, I saw one at the dealer, and the bearings are quite large, and I think that it will work out great. That is...

Well I found a dealer in town, it is 4.15" diameter body, and they said that they haven't had one return for repairs, and they are the only milwaukee repair center around, so that is good news.

Try these guys, they might have something like that, if they don't I think that they can custom make them. http://www.gortite.com/bellows.htm

I was wondering if anybody has the milwaukee 3.5 horsepower router. If you do have it what do you think? What is the body diameter? I was wondering if it would work in a porter cable router mount....

you're right, I forgot to mention what motors I was thinking about, I thinking about two of http://www.kelinginc.net/KL34H280_45_4A.pdf
these and one of these...

What do you think about 4 stacked 300W power supplies for the power? that would give me 15A and 48V. I think that would probably work out, but what do you all think?

I don't have my router set up yet, so I haven't tested this yet, but I found a 1/8th inch end mill that cuts steel at 12,000 rpm, and even certian stainless steels at 9,500 rpm. It is a duramill...

One more thing, the rack and pinion is probably the major limiting factor for the accuracy, vee rails if properly pre-loaded are generally quite accurate, which is what the shop bot has. Also wood...

It seems like the only benifit of the v rails would be that the bishop wisecarver rails would be hardened where yours aren't currently. The hiwin style (assuming you are talking about some of the...

Here are some pics of the gantry, the y axis vee bearings and rails, the z axis linear bearings and the x axis thk35 linear bearings. I have am going to use two rails and 4 carriages for the z axis,...

Well, I have started my router build. I am making it out of 8020 exrusions, and it will be used to cut mostly aluminum, also some abs will be cut with it. It will be 50x36, with a cutting area of...

Post up some pics of what you have, and the sizes of the parts for more help. Geckos are always good drivers and the motor size depends on what you want to cut and how fast, it also depends on the...

Ballscrews and nuts don't wear out very rapidly at all, they are quite hard, so you shouldn't have to adjust it too often.

What do you mean neither does rotating them, if you have two ballnuts, and you rotate 1 of them, you will be able to eliminate your backlash. With one ballnut, there aren't as many advantages to...

Well, that is how I plan on doing mine, I think it will solve a few problems, one is that you don't have to take the ballnuts off to install the dual ballnuts, another is that you don't need to make...

I would prefer the dual nut setup. as far as the configuration if you are offering to sale these, and they were a good price, I think that people would design around them, but I think that it would...

If you are making a table that small there is no sense in using two ballscrews on one axis, the reason that they use the tandom ballscrews is if it is a longer table, and it is racking or doing other...

I have heard to not get the round steppers as well, and was wondering why?

I am assuming that you are building this machine from scratch, so here are some recomendations.

For those tolerances you really don't have many options besides ground ball screws/or precision acme...

I don't know the answer, but it would be helpful to answer a few questions. Are you using the stock screws and bearings?, and are you going direct drive or reducing/increasing the gear ratio? You...

One thing to keep in mind, a mill is not better than a router! They are different machines for different purposes. A good router can cut wood way faster than a mill, because the rapids are close to...

I just decided to search for rails again after not looking for a while and ended up with two 22.5 inch 2omm thk rails with two blocks each for 25 bucks, they are in excellent condition. I was lucky...

Try a 1/4 inch carbide endmill, they seem to have the best results, if you go over it at a slow rpm (slow for a router 14,000ish) use an oil of some sort, A9 seems to work the best, but WD-40 will...