My First Setback...
by
, 09-25-2009 at 11:07 PM (6392 Views)
Well it had to happen. Although, I did not expect it to happen on the first day.
Let me explain. In my over-ambitious lust for a new project, I ignored the first rule of carpentry. "Measure twice, cut once." While I never got as far as the cutting stage before I realized a potentiel disaster, I will admit, for a couple of hours, I was at a loss on how to solve the dilema that unfolded as I drifted off to sleep.
In my rush to get the MDF base glued up, I neglected to relize that 6 layers of MDF when glued up, become a solid mass that weighs in excess of 100 pounds and measures just under 4 and a half inches thick.
My original plan was to glue up the panels and then square off the base on our panel saw. It was a great plan until I realized as I was falling asleep that night, our panel saw can only cut a thickness of just over 3 inches.
The first solution came to me as I was driving to work this morning. I would stand the base up on one side and use the jointer to square up that side. I would then use the panel saw to cut as high as it could into the base. At that point, I would break off the MDF and then use a flush trim router bit to work my way around the base.
Did I mention that this thing already weighs well over 100 pounds?
I knew it could be done, but I also knew there had to be an easier and safer way.
Well, ironically, I used a CNC Machine to help me build my first CNC Machine.
IMG_5439.JPG
Setting the base on my CAMaster, I created a vector that measured 31 by 48 inches. Using a 5 inch long 1/2 inch ball mill, there was just enough Z height to just squeeze over the top of the base by 3/8ths of an inch. With this bit, I was able to easily square up the base and cut the MDF to a depth of 3 and 3/8ths of an inch. When finished, I flipped the piece over, and proceeded to use a 1 and a half inch long flush trim bit with a 3 HP router.
IMG_5443.JPG
The day started on a bad note but ended on a good one. I will begin to wrap the perimeter of the base next week. After that, the linear glide rails for the gantry will be installed.
IMG_5444.JPG
Suggestions from others are welcome on this blog. If you have a tip or trick that will enable someone to square off a thick panel, please do not hesitate to post. I offered two solutions, one of which is potentiely dangerous and I do not endorse anyone trying it on something this heavy. The other is not an option for some, because not everyone has a CNC Machine at their disposal.