garageFab.cc

This is mini-router assembly in progress. The Y, Z and X stage are already assembled, working on the base now. I wanted to do a video timelapse of the whole thing, but as I went into several dead ends where I had to go back a couple of steps and re-assemble or re-align something differently, I thought I'll do clean timelapse when there are documented steps.

I've also had several issues with the assembly that aren't showstoppers but are still important:

Even if a rectangular frame (such as stage assembly) has all corners at 90 degrees, it can still be out of alignment by having one corner out of plane with other corners. It seems obvious but I didn't check for it and the Z stage (the one with three horizontal angles) ended up like that with one corner about 1/16" out of plane. Because I noticed it much later in the process, I decided to continue the assembly to see what the impact is going to be (I guess a curve instead of a line in Y direction). I think this problem should be preventable with true flat surface for assembly.

Alignment of shaft mounts is important, and it's worth taking time to install the leadscrews as soon as possible and ensure smooth rotation before space around the shaft mounts becomes cluttered. Nut/spring washer/nut combo can be secured on one end before leadscrew is installed.

Leadnut mount in sliding element can actually be aligned after shaft mounts are secured - and it's probably better that way as it will have the least strain.

All-thread rod leadscrews can have bad spots on them. They are not that bad with just a nut on, but when you have twin leadscrews connected by the belt, driving coupling nuts clamped in certain position, depending on the alignment, you may have to apply significant force on the pulley to get past a bad spot. I'm planning to battle this with WD-40.

Measuring N inches between angles using N other angles laid side by side is quick and accurate.  For example I used this to measure spacing between rails for X stage in the base.