Anil - kindly PM me the details of your timing pulley ( spec and cost)

RGDS
Irfan

Irfan, PM sent

Welding Y-Car problem
 

Gerald please help, while welding Y-Car, I end up with gap on both sides where bent part of 10 30 422 meets 10 30 455, pictures below. I think the 51 deg angle is not bent fully, please guide me what to do with the gap !!
Attachment 7086
Attachment 7085

Meanwhile I keep cutting and preparing steel for the table...
Attachment 7087

Just push the thin plate closed with 2 fingers and weld it . . . .while the thick plate stays vertical.

Thanks Gerald, but I am not able to move it by hand, its hard (mine was cut from 3mm thick as the laser company didn't had 2mm plate in stock). Foolish I am, tried to fix by blow of hammer and the gap widened :o .

Then you need to apply force with a clamp. Once you make the first small weld, check it all for square again. You can put a spacer block (or even the spider) in the center and then put clamps right across both sides and pull them in together.

OK, great, I'll get clamps of that size and try, Thanks a lot

Another problem I created is missing table offset w.r.t beams while welding main beams to cross members, Luckily not yet welded table legs so going to grind open the welds for re-welding. Any other option do I have other than opening and re-welding ??

Its not that I was not aware of offset but I was so focused on aligning/leveling/centering everything that I even centered the table and beam :)

Table Welding completed today :) No photos for this as I work in small room and not able to capture the whole table with my camera.
Attachment 7193

Welding was not that hard, I guess the rail cutting & grinding is the harder one :p

Hi Anil,

good work till now. I think everybody leaves the rails till the very end. Me too.
Good luck with your build

Claus

Thanks Claus, I don't have space so now as the table is done, somehow I have to cut and grind the rails on it, in fact everything now on is going to be done on MM table as It already filled up all the space.

Started with next major part, the Rails (with of course skate method). For me the only option is to do it inside and the only working space I have is MM table. Here is my setup for cutting..
Attachment 7264
The only thing I had and can trust for flatness was this Granite tabletop :), got the permission to use it with a promise that the first thing MM is going to do will be a tabletop.
Attachment 7265

Only a small portion cut and its all mess inside already ..
Attachment 7266

Check for fire risk . . . . that table on the right looks like it has some rags, paper & chemicals on top or underneath? It will also be easier to clean up if you clear all the stuff off the table first.

Thanks Gerald, I am clearing all that stuff now before going any further. Anyone reading this please take all the care and do it outside in open ( I had to do it this way as I don't have other option)

Cutting of rails done :)
 

Cutting of angles to 28mm completed, next going to level and smooth the top of the rails flat a bit with grinder and then grind V :)

Used 10 discs because could not utilize the whole discs as the angles were 65mmx65mm. One tip to add here (may be its already said) is to level and get the disc parallel to cutting surface, otherwise disc is caught in groove and may break and wear fast.
Attachment 7272

I was lucky enough to just cut all of them with what i had (10 discs) as you can see i had to break last a little part of rail as the last disc was not enough to cut through :)
Attachment 7273

In t1st pic, look how small my lathe looks in comparison to MM table

So you consumed all discs we purchased :)
Just to add I got another bigger pulley from M. bazar.
You also need to check angle for v cutting.
(Note - I was with Anil on 23.11.09 together we explored market)

We purchased only 5 that day, I needed another 5 and got them later :), Yes I had a thought about the angle before and asked the question in this thread, will keep in mind to get the angle match rollers to best i can, thanks for reminding.

Wondering today how fast time passes while working on MM, its been a month since started MM build :)
Well, little more progress as the rails grinding completed, no pics for this :( but yes a nice pic of grinding a little V on hand as a reminder to be more cautious and respectful with steel & machines.
Attachment 7376

Moving on to gantry, drilling the pilot in flat bar, y-rail and gantry tube all in one go by clamping together.
Attachment 7374

And finally a welded gantry:D, small twist but seems fine.
Attachment 7375

No, room is always not as dirty as its is now :eek: this is a pic from last month when I started the build.
Attachment 7378

And Yes I do have a lot of help available :)
Attachment 7377

Hello Anil,

sorry about that V-Cut in your hand. As a doctor I usually have always a medi kit around, but I think it will be cured by the time I arrive!:)

Greetings
Claus

See, tapping threads is child's work . . . :)

Correct Gerald :)
By the way I am using a small 300W drill to tap all threads and its working fine for me. Though 300W is far less power than required but still its faster than doing manually.

Your are right, It already started healing already and you might not notice it by the time you arrive :)

What can I say : Welcome to the club... A few months ago I cut my self with the grinder. During the construction process I was electocuted, cut, burned, etc. But all was left behind when MM start to make dust and chips :).
Claudiu its right : medical kit its a must in a workshop :D.

Avo Marius, you were cut, burned and electrocuted and you havn't sued the owner of the MechMate site for all these injuries? :(

They got out ALIVE - and that was enough for them not to complain :D

Getting out ALIVE is THE problem (for Gerald), DEAD can't complain :)

Everyone please check orientation :)
 

Gantry set on the X-rails finally..
Attachment 7425

and being tested for smooth ride
Attachment 7426

please check for the Y-car orientation w.r.t gantry, the first pic below is taken from 0,0 corner(0,0 closer to camera).

Yes, X-rails hangs over beams because of wrong offset calculation again by me :( , Need to weld a piece there before closing ends of beams.
Attachment 7423
Attachment 7424

Great work Anil. All the best. Waiting to see the machine working. Is our Mini Router working? If yes post me a picture of the same.

Anil, the orientation is correct.

Hi,

Good Progress, Love see them Blue.

Vishnu

Thanks Gerald for confirming quickly.

Thanks Pady :), We discuss only the BIG machine here, I'll send you pics of other machine in mail.

Thanks Vishnu, Paint job will be soon :)