Looks sharp!

 

Looks great! I use an old wood chisel to get rid of the nubs on those corner brackets (then touch up with a file if needed). That works pretty well too.

 

I haven't tried Scotty's method, I will have to now that I know - but I have found it easy (though maybe a bit irritating) to file the corner nubs off and to cut the aluminum brackets with a hacksaw within short order - so yes, soft I agree.

 

how to do ensure squareness of the brackets?

 

Rob, from your notes it sounds like you've already got this thing running. Can't wait to see more details of the build! (Including cabinet and clamping system.)

I Hope you will also include a short vid of that beauty cutting! Looks like the care with which you built it would ensure that calibration was a breeze.

I also noticed you have a door for one of your tables (I think). I had forgotten that I have a couple of those when I was building (darn!). Ready-made torsion boxes!

Anyway - keep it coming! Definitely a contender in the contest IMO. (I am very envious of your workshop, btw!)

 

I built an XL last year, but I have to say I'm embarrassed when I see your great workshop, you've done a great job! You might see the state of mine here https://1drv.ms/f/s!AlBVQey2XMxNgSUOryS6sRDkx8UQ

On the plus side, my modification to increase the Z by about 4" has proven to be well worthwhile and I haven't found any problems with loss of rigidity; I've also chosen Vcarve and found it to be really good, a bargain!

 

Hi Rob,
Yes, the normal Z length is really too small to do much. I put the cramp bars onto locating pins secured in the spoiler board, then milled the top of the bars flat; I can remove them easily if needed to work off the spoiler board, but to be honest I've only used the clamps to date. Some of the images show my first attempt using the fixed cast clamp heads, I've improved this by routing a slot across the cramping bars and inserting an oak bar to clamp against.
https://1drv.ms/i/s!AlBVQey2XMxNgXciEdv8MOiOXhEW
So normally I clamp the workpiece directly but for small parts I make a jig out of MDF and clamp that.

I'm about to install a chinese VFD spindle, hoping to program variable Spindle Speed from vcarve etc..

Cheers, Geoff

 

Hi,
Like Rob, I've had a go at keeping the chips under control. My system was 3 pieces of 5mm ply mounted vertically, like Rob's, but attached to the table with 1" sq batten, so that's 2 sides and back. It does help a lot, I could sweep out most of the chips off the table towards the open front but I did a job some time ago now where I needed to remove them for access of a large part, and they haven't gone back yet! The XL design keeps chips away from the lead screws and I'm just using a manual vacuum when I've finished a job. Good luck with you build.
Cheers, Geoff

 

Hi Craig, thanks for your comments. I should say that such a system can sometimes lift the workpiece slightly vertically as you tighten, so there can be a gap between workpiece and bars; this is caused by the centre of pressure differing in Z front to back. So if this matters, it takes a bit of care to make sure that the clamping forces pulls the part down and not up; so a thinner piece of oak sitting between the clamps and workpiece in my situation is normally the answer, in addition to a bit of manly downward pressure on the workpiece as you tighten up.
Cheers, Geoff

 

Hi Rob:

I really like your build. I ordered a standard size C-Beam bundle a few days ago and will be basing my build on yours, including a bit of extension to the Z axis. I'm also leaning towards the same UC100 and G540 setup from Vince. If you don't mind, I have a couple questions about your experience with that control system.

1. From his videos, the fan is definitely loud. Is it bearable?

2. I see you have put the controller case in your cabinet. I imagine that quiets things down, but how are you doing on temperature within the controller? Do you have the temperature auto cutoff switch on the G540 itself, and if so, has it ever cut out on you?

3. Did you evaluate the UCCNC software for the UC100 or decide to go with Mach 3 from the beginning? I'm rather new at this and think that maybe UCCNC would be easier for me to start off.