How To Assemble The Frame
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Now that we've got all the parts cut, we're ready to take apart the temporary frame and build the final machine!
Disassemble the temporary frame. Keep all of the parts, we will need them again. Sort the parts in an organized manner so that nothing is lost.
Collect each of the three lengths of 2x4, and each of the three angle braces that you cut in the last step. You should have two of each length of 2x4 and four of each shape of angle bracket.
Lay out the 2x4 sections in the way that they will go together which will be like this:
In case you didn't label them, here are the lengths of each part:
Attach each brace with four of the short wood screws provided. It is a good idea to drill pilot holes for these screws if you have access to a drill. You should note that the longest board will be the front facing part of the frame, and the shortest section will be on the floor, so do your best to make sure that the braces are flush or slightly retracted.
Flip the leg over, and attach the braces on the back side. You will want to make sure that both frames are as identical as possible in regards to their angles.
Note: The engraved numbers will be face down this time
Repeat steps 2-6 for the second leg. They are identical.
Attach the two remaining 12.5cm (5in) leg piece #1 segments to the back of the 4x8 sheet of plywood using four wood screws each 55cm (21.5in) from each edge.
The legs will ultimately rest on these mounting points.
This step requires two people.
With the legs standing upright, lift the frame and set it on top. Then, using the short wood screws provided, attach the frame to the legs by screwing through the front of the 4x8 sheet and into the legs.
Screw the plywood front and 2x4 back of each arm.
Don't forget, one arm is the mirror image of the other.
Attach the motor mounting plates to the arms by screwing through the plywood and into the 2x4. Use at least 6 screws in this step, this joint is under significant tension.
Attach the motor mounts to the arms using the short wood screws, then attach the motors to the motor mounts using the bolts. Attach the sprockets using the set screw and Allen wrench.
It is easier to attach the motors while they are low down than to attach them once the arms are in place.
Attach each of the arms by screwing through the backing of the machine and into the arm.
Attach the chain guide using one of the long screws provided and the nylon guide. Leave the screw loose enough that the nylon guide is free to rotate.
Attach the remaining 10 foot 2x4 to the legs below the main work area using the long wood screws provided. Drilling pilot holes is a good idea if you have a drill.
Attach the chains to the motor mounting plates using the cotter pins, then sting the chain over the motor sprockets.
Attach the chain tension bungee system which will function the same as on the temporary frame. You can review the complete setup instructions from the temporary frame here
Reconnect the machine's electronics. You can review the instructions to assemble the electronics here
Round over the edges of the sled using either a round over router bit, or sand paper.
Attach the hardware to the sled using the provided bolts and nuts. The bricks are held in place with the two long bolts each and the wooden brick holders, while the chain brackets will function identically to on the temporary sled.
With the new sled, you should do a recalibration. If you still have your measurements, you can skip the motor distance measurement using the skip button and manually enter the following measurements in Ground Control: motor-to-motor distance, rotational distance, motor-to-top-of-work-piece distance.
Before you start building, be sure to review the Safety Guide.
If you have a z-axis that you are ready to install, you can find instructions to help with that here
