Wanted to share my Xcarve Build. Which I have Named Sam-Bo.
I upgraded the Y-axis Rails to accommodate 1800mm Makerslides. To reduce any Side to Side flex, I bolted a 20x40mm extrusion to the inside of each Y maker slide. I attached this 20x40mm extrusion to the maker slide using 3/4" aluminum angle iron, Drilled every 6" on alternating sides. This took away all side to side flex. In Hindsight, i would rather use 2.5" angle Iron for this attachment. This would have done two things. First, the piece of angle iron that runs horizontal and attaches to the 20x40mm extrusion would hang over the edge about an inch (this could be trimmed down some on a table saw if so desired). In Theory, This flap would help keep dust from blowing up as bad at the edge of my table, if anything it would force the dust back toward the center of the table. Then the Vertical arm of Angle iron will act as a dust shield for the belts on the Y rails. If i recall correctly this vertical dust shield could be up to 2 3/4" tall. This entire modification adds substantial increase in strength and rigidity, not to mention dust shields (if using taller angle iron), to the Y axis.I am very Pleased with the results
Since I decided to scrap the entire waste board area of my machine, I needed something Flat and stable to replace it with. I chose to build a torsion box from 20x40 and 40x40 extrusion with 3/4" MDF skins on both sides. This table does have a few hidden designs but those are null and void at the current time, modifications are scheduled in the future. I am Very happy with this temporary table. soon I will be rebuilding the table with a torsion box built of 18ply baltic birch, in much more of a permanent location. for now it is on top of a spare workbench with the back of the machine supported by a saw horse. The Table is heavy and solid for this machine. thought about filling it with sand, but figured that would be over kill, not to mention cleaning up the sand in the shop and my aching back if and when I have to move this table.
I decided to use the endplates basically just for belt tensioning mounts. This required an alternate method to attach the Y rails to the new table. I chose to stack four pieces of 3/4" MDF, in Hindsight I wish that i had chosen six or eight pieces, but for the stock Z`axis, four layers (approximately 3"/76mm) IS the Perfect amount. Eventually, I will be modifying the Zaxis, when this is performed, then additional risers will be installed.
For my Worksurface/Wasteboard, I decided to use seven pieces of T-track embedded into the surface. I wanted a waste board that I could resurface multiple times, so i evenly mounted the T-tracks to the top of the extrusion torsion box table exactly 115mm apart. This allowed me to rip six pieces of 3/4"MDF 125mm wide by 49" long. Placed a 5.5mm rabbet on the bottom of each long edge and snapped these slats down between the T-tracks. this left the perfect gap for hold down bolts to access the T-tracks. EXTREMELY PLEASED with the results. these slats are now easily replaceable when the table gets chewed down. I can even switch them end for end and side to side incase i use one area of the table more than another. I plan on mounting these slats to the table using inserts in the table top and Nylon 1/4"-20 bolts securing the slats, this way no harm will come to my cutter heads incase they accidentally come into contact with the bolts.
these slats will get sealed with sanding sealer to help reduce moisture absorption as much as possible. and all other MDF will also be sealed before the job is done. These slats are also easily replaceable by cutting lengths off the edge of a sheet of MDF and adding simple rabbets. One sheet of 4x8 MDF will resurface the T-track area of my table exactly 3 times.
The T-track sits below the surface of the slats nearly 10mm. this is a lot of space for repeat bed leveling. with a 1 1/4" surfacing bit, I have full access to the entire bed, even with the added 20x40mm extrusions protruding in from each Y-rail.
These modifications result in Exactly 3.5"/90mm of Clearance for the Z-carrage. This allows for the exact same measurement for the Spindle, SO it is MAX capabilities with the stock Z, and this is with the Z axis Lower V-wheels right on the end of the stock maker slide. Of course this will increase slightly or decrease slightly depending on the extent of surfacing performed to the new work surface.
I am currently using a 3d printed dust shoe. This specific unit works well and serves its purpose. the biggest issue that i have with it is loosing 1.5 of usable workspace and it can’t clear some clamps. this is unacceptable and is requiring a new design with much more clearance. I have already crashed it multiple times. the first few times, it was repaired with acetone. but after my most recent collision, the entire unit was coated in thin CA glue. Seems to be holding up for the time being.
The Z-rails included 1 1/2" aluminum Tee between the maker slides and 7 furniture bolts holding it all together.
Some of you might be wondering why Silver rails and no black rails. They are in my storage room. hint hint I see stand alone Laser cutter in the near future.
You might also notice that my drag chains are reversed as well and i upgraded to a 40mm drag chain for the Y axis.
For the Z axis, I extended the two m5 bolts and added lock nuts to them replacing the stock bolts holding the ACME rod bearing in place. This gave me a positive STOP that keeps my Z Limit switch from being crushed.Also added a thumb wheel to the top of the ACME rod. and of course the DWP611 Spindle.
In the photo, there is an Emergency Stop enclosure mounted on the Very front of the Table. After this photo was taken, I decided to drop that enclosure under the front edge of the table. The button extends past the front edge of the table by approximately 3/4" for easy access.
I also built a custom electronics housing/ control box similar to the X-controller, but I will share that stage of the build later
