What leg length angle did you use ?

The drawings call for 65mm but I had to use 50mm.

What
 

Not sure what you are askings

What size angle did you use to make your X & Y axis rails from.

2 x 2 x .250 angle

Plans call for 2.5".

Can you post a picture of your rails and drilled holes.

You should not have a problem if you have used 2'' x 2'' (50.8mm)

Time Out
 

Well I found out that I used the wrong size angle to make the x and y rails so I ordered from the local steel yard and it won't be in until tomorrow. I decided to clean another section of the garage out and got side tracked on modifying by tube bender. I added the hydraulic with pneumatic assist to my JD3 Bender. No way am I going to manually bend 2 inch tube. I designed a steel base with casters to move it around. I was able to get it drilled and mounted so I can put the casters on and I will be ready to go. I love the screeeeching sound of steel bending, unless it is a car accident. Later, tomorrow I cut new rails. Oh, If Mike reads this I found the spider I guess I needed two. I found it with the MIG welder waiting to get welded.

Just a suggestion, keep all your posts in a single thread so we can better follow your progress and help when we can. Normally there is only one build thread per build (some people do multiple builds, so get multiple threads).

Thanks

I consolidated these into one thread so you can go forward from here in one thread !!

New Steel, New Task
 

Well since I was told that I used the wrong size angle for my guides. I went over to the steel warehouse to pick up my order. I started to cut the 10 foot rails for x-axis and two hours later I was done. It was 86 today so I was glad to get done. Now for the y-axis. What, I can't cut 2 1/2 with the skate. So I drug out the band saw put it in the upright position, put on the optional table(sucks, I am going to replace it later). I put a guide on and measured it. I was ready to cut. Here I was half way through and I was ready to die. This is not the way to do this.
http://i1296.photobucket.com/albums/...pse25314d4.jpg
Notice the blade guide, that is as far as it goes down. Not safe. If you look to the left on the red cart is a Miller Plasma cutter. I am going to try that on the last y-rail. Well I ordered a new skate from Metalhead and I will see if I can make these things pointy.
Well the little blue mechmate fairy (granddaughter Anna) stopped by the house and gave me three wishes. I wish I didn't hurt so much. I wish I didn't hurt so much. I wish I had a hot tube, I do so I am going to go jump(crawl) in.
http://i1296.photobucket.com/albums/...ps96fe754a.jpg

Ok, who ordered the spaceship ?

Cool, what process did you go through to make it

Beam me up Scotty. Must, get, home.

Process
 

As Ken C said, search for a .dwg or .dxf file or draw one from scratch.
Edit and scale the file to suit your piece of wood.
Save the file as a .dxf.
Put the file through your cam/ post processor to create the n.c. program.

As I do not have a planer thicknesser I faced both sides of the board on the router.
Cut the job. Sand, seal, stain/ varnish.
Fill the engraving with paint, wipe off the excess.
Thats about it.

De railed
 

by the way the close to the edge referred to the band YES.
Well all the new rails are cut. I never did get the plasma cutter working.
exchanged the two consumable parts. I rewired it for 230volts. The air compressor is plenty big to handle the air and pressure. but that will a task for another day.
I did get finished with cutting all the new rails. I ordered a new skate from Mike and will start putting a pretty little v on these guys when it arrives. It has been raining the last couple days so that is slowing progress. I would like to put slots in the rails so I can adjust them but I will need to dig the mill out of the corner and put it up front.
If I get this done I can start to plan assembly of the y-axis. Later

Plasma
 

Well I guess the plasma cutter didn't want to be used to cut the rail but I did get it working. I need to buy a inline dryer.
Well it finally hit me. I went out and moved some of the machines around and put the mill up front in the double car side. Now I can hang the ten foot rails out the garage opening and not worry about pumping into things.

New Skate
 

I received the new skate I ordered from Mike. I found six of the eight bearings in my computer room. I stash parts there now since I am really lousy at organization. While I found the last 2 in the garage today while looking for nuts and bolts for the skate.
I really hate to admit it but Jimmy Carter was right when he tried to convert us to metric. I have a mixed collection of both. I had to get no# 12 metric bolts that fit the bearings. I drilled them off centered to give them the needed cam action. Hopefully have the skate finished tomorrow and start beveling.
Tonight I go shopping with the wife looking for a new microwave.

anyone have input on rail height? I believe it is suppose to be 1.100 inches.

Rail Grinder Notes
 

Note, Ryobi grinder AG403 4 1/2 inch grinder is a perfect fit for the rail cutter/grinder. Other Ryobi grinder does not fit grinder and requires grinding to fit. Warning when grinder is setup to grind v pattern on rail, the grind wheel is exposed. Wear gloves and eye (full face would be best) protection when grinding. When grinding in one direction sparks are thrown directly into your face.

Grinder Completed
 

Completed making parts for grinder. I was able to bolt it all together after a couple trips to the hardware store. Started testing it. Vibration requires that lock washer be used. Run flapper wheel grinder over rail where grinder bearings run. This may allow bearings to be set to tighter tolerances.

Are you using a sanding disk with a grinding wheel as a backer. This will save you hours of grinding. Also HF's 9.99 grinder fits with no mods as well.

Thanks
 

Is the sanding disk used to finish/polish the the rail.
I wouldn't think it would cut faster. Let me know. Thanks

Use 40 grit and it makes the metal disappear way faster and doesn't glaze. Then move up the grits if you like. If I remember I was able to bevel one of the rails in 15 minutes after I used all the others for learning.

36 grit is what I used....made the 45 deg profile in about 15 minutes for each rail. Finish with 80 grit. Remember to use a REAL grinder disk as a hard backer

Thanks
 

Thanks Rus and Sean. I do have concerns about how the skate "wobbles". It is not really steady. Maybe this is because I am at the beginning of the process. Is it because it is still cutting the square edge and forming the bevel. I guess I will find out tomorrow.

hmmm....... I don't remember mine wobbling. I do remember going one direction it would lift off and going the other direction it would dig in. The eccentric bushings took care of I would think would cause wobble. I also didn't hold the grinder itself. I mounted handles on my skate. Basically Eye bolts that adjusted the height of the skate.

3M 06394 VHB Tape
 

Purchased 3M 06394 VHB Tape on Ebay. I am almost readt to mount gear track on rails. Should be finished with rails by time tape arrives.

Gear Reduction Drives
 

Started to work on drives. Ordered the following parts from

Standard Drive Products. www.sdp-si.com

Belt (5)- A 6B 3-080037 8.16 40.80
Driven Pulley (4) - A 6A 3-72NF03716 33.73 134.92
Drive Pulley (4) -A 6A 3-18H3716 11.58 46.32
Bearings (10) - Ebay FR8Z Bearings 25.00

Hurshy, are your belts the fiberglass or kevlar?

Kevlar

Mine too, I just hope I don't crash the thing and do more damage because the belts didn't break.:eek: