How To Assemble The Frame
Now that we've got all the parts cut, we're ready to take apart the temporary frame and build the final machine!
(These instructions are in progress)
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.
As I was going through this process I realized that it's easier if leg piece #1 is actually cut into two pieces as shown below. I will go back and rework the directions from the beginning as soon as possible.
If you have already cut the leg pieces, cut leg piece #1 into one 12.5cm (5 in) section, and one remainder section which will be leg piece #6.
Collect each of the five lengths of 2x4, and each of the five 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.
Note, you may want to use your remaining 10' 2x4 to check that everything lines up. Leg piece #1 does not attach in this step.
Flip the leg over, and attach the braces on the back side
Repeat steps 2-5 for the second leg. It can help to build the second on on top of the first one to insure that they are the same.
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 end.
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 together the front and back section of each arm.
Don't forget, one arm is the mirror image of the other.
Using the U-bolts, attach the motor mounting plates to the arms
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.
Community note: Attaching these by screwing from the back of the machine through the arm and into the bed of the machine will hide the screw heads.
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.
Remove the cotter rings from the ends of each chain. Attach the chains to the motor mounting plates using the large 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 any other method you would like.
Attach the hardware to the sled using the provided bolts and nuts. The bricks are held in place with the two long bolts, while the chain brackets will function identically to on the temporary sled.
Attach your router to the sled by replacing the router base-plate with the sled.
Attach the bricks by using the four long bolts and the wooden brick holders to keep them in place.
{picture of bricks attached}
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