IMPORTANT- READ BEFORE USING THESE PLANS Thank you for buying the CNC Router/Engraver Design Package

By using this package the buyer agrees to all of the following terms and conditions.

1. Electrical, electronic, computer interface & software installation and setup instructions are not included with this

package. There is extensive and complete information available on the Internet from vendors of CNC system kits such as www.xylotex.com and www.hobbycnc.com free of charge. It is intended that the builder make his own selections based on his own preferences and budget.

2. All responsibility with building and operation of the machine built from these plans rest solely with the purchaser. 3. Purchaser agrees to hold seller harmless in any event of accident or loss. 4. Purchaser agrees to allow only one machine to be built from these plans for personal use. License and document

is not transferable. 5. Purchaser agrees to all U.S. Copyright laws applicable and will not make copies for distribution or sale. Legal

owner, for purposes of making one machine, may make working copies only.

Limited Warranty Seller will replace any missing or errant sheets free of change. Revisions and additional design documents will be available on the Yahoo CNC_Router-Engraver Group. In no event will seller be held liable for direct or indirect damages resulting from the building and/or operation of machine.

QUICK INTRODUCTION

Since this is essentially a redesign of my original machine I will skip the whining about being ripped-off for a bunch of poorly done sketches billed as HobbyCNC Plans. That was my initial motivation for designing this machine. What this is, is a complete design package that includes not only cross referenced drawings and parts list but includes flat pattern drawings for all of the parts you need to make. These are Birch Baltic plywood, not to be confused with ordinary plywood, (it is made of 13 solid plies of wood best known and used for tool making and boat building for its strength and stability). It can be bought at any hardwood or cabinet supply store. 6061-T651 aluminum (a strong but easy to machine alloy) is used for the head and tool plate. HDPE is used for bearing blocks (it holds good tolerances with standard Forstner bits and is excellent for mounting bearings). Some are selling machine plans made entirely of HDPE but this material is too elastic and curls too much to make an accurate machine of any useful size. Some are selling MDF plans but MDF has weak structural properties. Having a thirty-year background in design engineering and detailing for the aerospace industry, I know that making accurate parts can be expense and difficult with costly tooling involved. To make this simpler I have included an easy to make drilling fixture that ensures that your parts are accurately mated. The main tools you do need to make this machine are a table saw, a drill press, the drilling fixture (drawing included) and ordinary hand tools, twist drill bits, forstner bits, small tap set and countersink. These drawings are fully cross-referenced so that you can easily find where a part goes and have a full description of it. Here are simple guidelines for reading a parts list:

1. Find numbers are used to locate a part on a drawing (all parts either made or bought have a find number). 2. Quantity is the number of parts required to make one complete assembly. AR designation means as required. 3. Part numbers are the actual manufacturers’ part no. or the part you are fabricating, i.e. find no. 36 = part no.

97633A270 McMaster-Carr EXT RETAINING RING; find no. 29 = part no. -29 GANTRY STIFFENERS 4. Description is a name and the overall dimensions describing a part. 5. Material is the preferred material of the part. 6. Drawing location is the drawing sheet number(s) where the part is either dimensioned & detailed or located. 7. Manufacturer is the suggested source of the part (may be changed if you find a better source). 8. Notes are an extension of the description, material or manufacturer to help better describe the part.

Just remember the Parts List is the main document in a design package. Everything is located, described and sourced from it. It is your number one reference. At companies like Lockheed and Boeing it is drawing sheet #1. Your Notes sheet should be #2 as notes describe important information on how to interpret the drawings. Look them over first and use them for reference. They will answer most of your questions as well as setting the guidelines for making and assembling the parts. The lack of these two items is why many “plans” can become very confusing.

Included in this design package are:

1. Complete Parts List with Find Numbers, quantity, part number, full description, suggested material sources, and drawing locations.

2. Design Notes to aid in fabrication and assembly. 3. Isometric Assembly with references to sub-assemblies. 4. Top CNC Router/Engraver Assembly Drawing. 5. Fully detailed, color coded, sub-assemblies including hardware/motor isometric reference assembly. 6. Detail views showing how to assemble various sub-assemblies. 7. Material flat pattern drawing with overall finished dimensions for Baltic plywood parts. 8. Material flat pattern drawing with overall finished dimensions of all aluminum parts. 9. Material flat pattern drawing for HDPE parts. 10. Drawing of typical work-piece mount hardware and wire routing. 11. Detailed drawing for making and using the Drilling Fixture. 12. Fastener location reference drawings for the Table Assembly and Gantry Assembly 13. List of Internet & local hardware vendors 14. Photo-realistic illustrations of all sub-assemblies.

Why I have done all of this? Well like many, who have been intrigued with do-it-your-self plans since I was very young, I have seen few truly easy to use plans. With the aid of 3D computer cad, rendering software and color printers this is easier to achieve now. I did not like the plans or designs I had seen, so, I knew I could do better. I have put a lot of time into refining this design to maximize strength, size and accuracy using easy to make parts for the homebuilder. I hope you agree and would like to here your comments or suggestions. Good, bad or ugly. No design is perfect and could use refinement. You can email me at unique_designs_1@yahoo.com with your comments or questions. All updates to these plans are available for download from the Yahoo CNC_Router-Engraver Group to all registered buyers. If you don’t receive an invitation to join the group email me to get access. Building tips and suggestions:

1. After you become familiar with the drawings and acquire the raw materials, cut out all of the plywood, aluminum and HDPE parts to finished sizes using the flat pattern drawings. Mark each piece with the part number and correct datum edges. After you finish the details and drilling on all the parts assembly will be much easier and accurate.

2. The second thing I did before I started building my first machine was to join the Xylotex Yahoo Users Group

http://groups.yahoo.com/group/Xylotex/ . I would read through their messages to learn what I was getting myself into. I saved many of these for future reference and learned a lot about using CNC while I was building my machine. DIY-CNC is another good Yahoo Group. CNC Zone http://www.cnczone.com/forums/ is a good forum that is also free to join.

3. These plans provide you with everything you need to build a complete CNC machine that will work with many CNC

driver/stepper motor kits or if you are advanced in CNC setup you can make your own selection of stepper motors and driver board. The motor mounts will take any NEMA 23 motors. I have not included information on setting up drivers and software to two good reasons. 1. All of the sellers of CNC driver kits have extensive information and support available for setting up their specific hardware and running various software programs on them. 2. If I did include such information it would likely make it more confusing to you and possibly violate copy writes.

4. Below are some of the systems and software on the Internet I have researched that are compatible and reasonably

priced:

Xylotex; http://www.xylotex.com/ Stepper World http://www.stepperworld.com/ Hobby CNC http://hobbycnc.com/ DesKAM http://www.deskam.com/ DeskART, DeskEngrave, DesKAM 2000 ArtSoft http://www.artsoftcontrols.com/ Mach 3 While I don’t endorse any particular one, all seem to be good systems with good support. I used the Xylotex 3-axis Complete System and Mach 3 software. The Xylotex User Group has set up files for Mach 2 and 3 software that anyone can download. StepperWorld systems come with a setup program to test and adjust your motors and driver.

5. If you choose to build the workstation/stand you should have enough material left over from a 5’ x 5’ sheet of Baltic plywood to make all of the panels for the stand. The A-frame metal legs come fully assembled making it very a quick and economical solution if you don’t have workbench space for your machine.

6. Leadscrews can vary in length. The motor mounts and bearing blocks in these plans are designed to use leadscrews

sold by Precision-CNC-Router, ebay seller premachine2004 which are 1 ¾” longer than thread size. In other words a 24” leadscrew is 25 ¾” long including machining on both ends. You can eliminate the motor mounts if you purchase exact size leadscrews.

7. Ebay seller metalconnections sells 6061-T651 aluminum, 10 pound minimum at $3.70 lb. Ten pounds is just enough

to buy 2 each of all the parts required if you want to play it safe. You can purchase stock for other projects if you feel safe with only one of each. Weight is cubic inches X .101. Thickness available: .250", .313", .375", .500", .625", .750", 1.00"

8. I bought 80% of my hardware from Enco www.use-enco.com If you plan on using this source and register for their

email specials ASAP they periodically have email offers for free shipping. I saved over $100 by taking advantage of the free shipping offers.

PARTS LIST (CONTINUED ON SHEET NO. 2 )

30 8 -30 GANTRY BEARING SHIM 2.0 X 2.0 HDPE CNC0002 FABRICATE (see FP00011FP layout) MAKE FROM FN8729 4 -29 GANTRY STIFFENERS 3.0 X 3.50 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8628 1 -28 GANTRY, NUT PLATE 3.00 X 4.25 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8627 1 -27 GANTRY BOTTOM 3.50 X 21.20 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8626 1 -26 GANTRY BOX SIDE 3.75 X 21.20 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8625 1 -25 GANTRY BOX SIDE 3.75 X 21.20 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8624 1 -24 GANTRY DOUBLER 3/4 X 8.0 X 5.75 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8623 1 -23 GANTRY END 3/4 X 8.0 X 18.0 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8622 1 -22 GANTRY DOUBLER 3/4 X 8.0 X 5.75 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8621 1 -21 GANTRY END 3/4 X 8.0 X 18.0 BPLY CNC0002 FABRICATE (see FP00013W layout) MAKE FROM FN8620 1 -20 TABLE TOP 3/4 X 20 1/2 X 36 BPLY CNC0001 FABRICATE (see FP00013W layout) MAKE FROM FN8619 1 -19 TABLE END 3/4 X 4 1/4 X 20 1/2 BPLY CNC0001 FABRICATE (see FP00013W layout) MAKE FROM FN8618 1 -18 TABLE END 3/4 X 4 1/4 X 20 1/2 BPLY CNC0001 FABRICATE (see FP00013W layout) MAKE FROM FN8617 2 H0878 Woodstock T-SLOT TRACK 36" ALUM CNC0001 amazon.com OR ROCKLER.COM PN 3603316 4 -16 ADJUSTABLE PADS 1 1/8 DIA VAR CNC0001 (LOCAL) 4pcs. $1.49, LOWES15 2 325-4345 ANGLE 1.500 X .125 X 48 6061 ALUM CNC0001 Enco 1 PC REQUIRED, 48.0" LENGTH, $11.9414 1 -14 .250 X 3.00 X 2.88 DREMEL MOUNT ALUM Ebay metalconnections (see FP00012AL layout)13 1 -13 .250 X 2.00 X 2.88 DREMEL MOUNT ALUM CNC0010 Ebay metalconnections (see FP00012AL layout)12 1 -12 .375 X 5.50 X 9.75 HEAD FACE PLT ALUM CNC0003 Ebay metalconnections (see FP00012AL layout)11 1 -11 .375 X 5.50 X 2.00 HEAD LWR PLT ALUM CNC0003 Ebay metalconnections (see FP00012AL layout)10 1 -10 .375 X 5.50 X 3.00 HEAD UPR PLT ALUM CNC0003 Ebay metalconnections (see FP00012AL layout)9 1 -9 .500 X 5.50 X 6.00 Z AXIS TOOL MNT ALUM CNC0004 Ebay metalconnections (see FP00012AL layout)8 1 -8 .500 X 2.88 X 3.25 DREMEL MOUNT HDPE CNC0009 FABRICATE (see FP00011FP layout) MAKE FROM FN887 1 -7 .500 X 1.50 X 2.00 BRNG BLOCK HDPE CNC0003 FABRICATE (see FP00011FP layout) MAKE FROM FN886 2 -6 .500 X 1.75 X 5.50 BRNG BLOCK HDPE CNC0004 FABRICATE (see FP00011FP layout) MAKE FROM FN885 2 -5 .500 X 1.75 X 5.50 Z BRNG BLOCK HDPE CNC0004 FABRICATE (see FP00011FP layout) MAKE FROM FN884 2 -4 .500 X 2.00 X 2.00 BRNG BLOCK HDPE CNC0001,2 FABRICATE (see FP00011FP layout) MAKE FROM FN883 2 -3 .500 X 2.00 X 6.50 HEAD BRNG BLOCK HDPE CNC0003 FABRICATE (see FP00011FP layout) MAKE FROM FN882 2 -2 .500 X 2.00 X 8.00 HEAD BRNG BLOCK HDPE CNC0003 FABRICATE (see FP00011FP layout) MAKE FROM FN881 3 -1 .500 X 2.50 X 2.50 MOTOR MOUNT HDPE CNC0009 FABRICATE (see FP00011FP layout) MAKE FROM FN88

FIND NO. QTY PART NO. DESCRIPTION MATL DWG LOC MFG NOTESSHEET 1 OF 4

PARTS LIST (CONTINUED ON SHEET NO. 3 )

60 1 -60 TEFLON MULTI-USE LUB 4OZ LUB NOT SHOWN (LOCAL) DuPONT 59 AR 891-2859 1/4 SIZE SPLIT LOCK WASHER ZPLT VARIOUS Enco QTY 100 (USE AS REQUIRED)58 AR 326-0476 1/4 SIZE FLAT WASHER SST VARIOUS Enco QTY 100 (USE AS REQUIRED)57 AR 326-0261 1/4-20 FINISHED FULL HEX NUT SST VARIOUS Enco QTY 100 (USE AS REQUIRED)56 6 510-1953 RADIAL BEARING STL CNC0003 Enco .31 ID X .88 OD X .275 T55 4 505-3354 .500 ID CLOSED LINEAR BEARING VAR CNC00010 Enco Pacific FRELON BEARING54 8 505-3355 .750 ID CLOSED LINEAR BEARING VAR CNC00010 Enco Pacific FRELON BEARING53 1 408-0029 1/2 OIL HARDENED DRILL ROD X 9.75 DROD CNC0001 Enco 3 FT52 2 408-0045 3/4 OIL HARDENED DRILL ROD X 24.0 DROD CNC0001 Enco 3 FT, QTY 251 2 408-0045 3/4 OIL HARDENED DRILL ROD X 36.0 DROD CNC0001 Enco 3 FT, QTY 250 2 891-5748 HUSKY KNOB 1 5/8DIA X 1/4-20 STL CNC0005 Enco $.96 ea49 16 -49 #10-24 X 1.0 SHCS ALLOY SCREW STL CNC0004 (LOCAL) MOTOR MOUNT48 16 -48 #10 SPLIT LOCK WASHER STL CNC0001 (LOCAL) MOTOR MOUNT47 8 505-3282 SHAFT COLLAR 1.0 ID STL CNC0006 Enco $.85 EA46 8 325-7583 3/4 ID X 1-1/8 OIL IMPG FLG BRNG BRNZ 01,02 Enco 1 OD X 1 1/8 LG 1 1/4 FLG $1.43 ea45 3 891-6315 SET SCREW COUPLING 1/4 BORE STL CNC0005 Enco 1/2 OD X 3/4 LG, $4.65 ea44 AR 430-0078 1/4-20 X 1-1/2 SHCS ALLOY STL CNC00010 Enco QTY 100 (USE AS REQUIRED)43 AR 433-0041 #10-24 FLAT HD CAP SCREW 1.0 STL CNC0003,4 Enco QTY 100, FOR HEAD, Z DRIVE, M/MOUNT42 1 9" 1/2-10 ACME Leadscrew W/Delrin Nut STL CNC00010 Ebay Precision-CNC-Router premachine200441 1 24" 1/2-10 ACME Leadscrew W/Delrin Nut STL CNC00010 Ebay Precision-CNC-Router premachine200440 1 36" 1/2-10 ACME Leadscrew W/Delrin Nut STL CNC00010 Ebay Precision-CNC-Router premachine200439 16 94115K121 O-RING AS568A DASH NO 121 NEOP CNC0007 McMstr-Carr 100pc $8.39 .116 X 1.047 ID X 1.254 (891-5956 Enco #)38 8 94115K115 O-RING AS568A DASH NO 115 NEOP CNC0004 McMstr-Carr 100pc $4.35 .103 X .674 ID X .88 (240-2535 Enco #)37 16 97633A340 EXT RETAINING RING FOR 1.25IN SHFT STL CNC0007 McMstr-Carr 30pc. $4.5936 8 97633A270 EXT RETAINING RING FOR .875IN SHFT STL CNC0007 McMstr-Carr 50pc. $6.0935 60 -35 SCREW SST SQDR X 1 1/4 LG SST CNC0001 (LOCAL) 2 BOX QTY 30 EA, FLAT HEAD DECK34 12 -34 SPACER Ø.500 X 1.625" LG ALUM CNC0009 (LOCAL) (SEE GENERAL NOTE 23)33 1 -33 8.0 X 24.0 X 22-24 GA STL CNC0002 (LOCAL) OR 16 GA ALUM BRACE & WIRE SUPPORT32 2 -32 5/16-24 SET SCREW 5/16 LG STL CNC0003 (LOCAL)31 44 -31 SCREW ROUND HD #10 X .75 STL SEE NOTE (LOCAL) CNC00014FAS

FIND NO. QTY PART NO. DESCRIPTION MATL DWG LOC MFG NOTESSHEET 2 OF 4

PARTS LIST (CONTINUED ON SHEET NO. 4 )

908988 1 319-5093 HDPE 1/2" X 12" X 24" WHITE HDPE CNC0011FPEnco FOR FABRICATION OF PN 1-5, 8 $18.7887 1 319-5084 HDPE 1/8" X 12" X 12" WHITE HDPE CNC0011FPEnco FOR FABRICATION OF PN 30 $3.3186 1 -88 3/4" X 5' X 5' BALTIC PLYWOOD PLY FP0013WD (LOCAL) FOR FABRICATION OF PN 18-2985 RAW MATERIALS REQUIRED FOR MAKING STRUCTURAL PARTS848382 2 -82 MOUNTING CLIP .75 X 1.25 STL/AL CNC0006 (LOCAL) 16GA STL OR 14GA AL, FOR NC SWITCH81 12 -81 #10 LK WASHER STL CNC0004 (LOCAL) CNC0003, CNC0002 FOR DELRIN NUT 80 12 -80 #10-24 X 1.50 SKHD CAP SCREW STL CNC0004 (LOCAL) CNC0003, CNC0002 FOR DELRIN NUT 79 2 -79 Ø.25 X 1.25 FLAT HD CAP SCREWSTL CNC0010 (LOCAL) (DREMEL MOUNT)78 1 -78 TABLE 3/4 X 14 X 15 PLY CNC0008 (LOCAL) MAKE FROM LEFTOVER PLYWOOD77 2 -77 SUPPORT 3/4 X 4 X 11 PLY CNC0008 (LOCAL) MAKE FROM LEFTOVER PLYWOOD76 2 -76 GUSSET 3/4 X 5 1/2 X 40 1/2 PLY CNC0008 (LOCAL) MAKE FROM LEFTOVER PLYWOOD75 1 -75 LOWER SHELF 3/4 X 16 X 40 1/2 PLY CNC0008 (LOCAL) MAKE FROM LEFTOVER PLYWOOD74 1 819-4020 STURDI-BILT Workbench Legs STL CNC0008 Enco WOODCRAFT.COM $22.0973 8 -73 TEE-NUT #10-24 STL CNC0007 Home Depot FOR MOUNT PADS72 8 -72 NUT 5/16-18 STL CNC0007 Home Depot FOR MOUNT PADS71 4 -71 ADJUSTABLE GLIDERS 5/16 (VAR) CNC0007 Home Depot FOR MOUNT PADS, 4 pcs $3.9970 4 -70 ANGLE .188 THK X 2 X 2 X 1.5 LG ALUM CNC0007 Enco MAKE FROM FN15 LEFTOVER ALUM ANGLE69 1 -69 #8 HEX NUT BRNZ CNC0010 (LOCAL) HOME DEPOT (DREMEL MOUNT)68 1 -68 #8 FLT WASHER BRNZ CNC0010 (LOCAL) HOME DEPOT (DREMEL MOUNT)67 1 -67 #8-32 X 1.62 LG RDHD SCREW BRNZ CNC0010 (LOCAL) HOME DEPOT (DREMEL MOUNT)66 12 -66 1/4" WIRE HANGERS PLAS CNC00011 (LOCAL) VARIOUS SIZE AND QUANTITIES AS NEEDED65 AR -65 WIRE (22ga. min.) WIRE CNC00011 (LOCAL) WIRE FOR NC LIMIT SWITCHES, AS REQUIRED64 1 Model 395 DREMEL ROTARY TOOL (VAR) CNC00011 (LOCAL) (OR TOOL HEAD AS SELECTED BY BUILDER)63 4 H0879 HOLD DOWN CLAMP FOR FN17 ALUM CNC00016 amazon.com FOR T-SLOT TRACKS$3.95 ea, (OPTIONAL)62 6 275-1548 MOMENTATY SWITCH NC (VAR) CNC00010 Radio Shack (SEE GENERAL NOTE 12)61 1 -61 TITEBOND WOOD GLUE, 8 OZ GLUE as required (LOCAL) (FOR ASSEMBLY OF PLYWOOD)

FIND NO. QTY PART NO. DESCRIPTION MATL DWG LOC MFG NOTES

SHEET 3 OF 4

PARTS LIST (END )

326-0469 #10L FLAT WASHER 18-8 SST CNC0002-4 Enco $3.24 per 100, .031 THK325-3316 10-32 SAE ELASTIC LOCKNUTS ZINC ZPLT CNC0002-4 Enco $2.16 per 100430-0068 10-32 X 1-1/2 SKT HD CAP SCREW ASTL CNC0002-4 Enco $8.11 per 100

CSX-0268-05 COMP SPRING .845 OD X .067WD X 2.5 302 SS CNC0002-4 Small Parts www.smallparts.com PK/5 $6.6581239 Heavy Duty Lifting Leveler STL N/A Rockler Rockler.com, 1 PACK QTY 4

101-1203 LIMIT SWITCH var N/A mouser mouser.com QTY 6OPTIONAL STAR KNOB AND BOLT 1/4" x 20 var N/A amazon.com for T-TracksFET-3/Dyn 3 Axis Stepper System w/o case var N/A Stepperwrld http://www.stepperworld.comOPTIONAL DM-4 Enclosure (case), PacTec Plastic N/A Mouser.com Mouser Part #: 616-72496-510-039OPTIONAL DesKAM, DeskART S/W N/A DesKAM http://www.deskam.com/OPTIONAL TurboCNC, Ace Converter S/W N/A DAK http://www.dakeng.com/turbo.htmlOPTIONAL Mach II & Mach III S/W N/A Artsoft http://www.artsoftcontrols.com/

REQUIRED PC RUNNING CNC SOFTWARE N/A Win2000 or XP Pro, see software requirements OPTIONAL CNC4PC BREAKOUT BOARD ELEC N/A CNC4PC For E-STOP http://www.cnc4pc.com/Store OPTIONAL Router Mount for Porter Cable Routers ALUM N/A K2cnc.com eBay seller titeone, CNC Router ad OPTIONAL Dremel Tool Mount, Holder $35 ALUM CNC00010 David Sattler purchase direct from davidmsattler@hotmail.com 3 AXIS STEP Xylotex 3 Axis Drive Box w/Motors CNC00010 Xylotex.com COMPLETE DRIVE BOX SYSTEM AS SHOWN $475

SYSTEM & Cables (can be purchased in kit for $345 without case & cables) THE ABOVE ARE ONLY SUGGESTED HARDWARE & SOFTWARE NO ENDORSEMENT IS IMPLIED

(SETUP AND OPERATION ARE RESPONSIBILITY OF BUILDER & SUPPLIER) - OPTIONAL COMPONENTS & PARTS -

9695949392 6 -92 Delrin Acme Flange Nuts 1/2-10 RH DELRIN CNC0002-4 (SEE NOTE) eBAY seller widgitmasterinc $5.25 ea91 OPTIONAL ANTI-BACKLASH NUT

FIND NO. QTY PART NO. DESCRIPTION MATL DWG LOC MFG NOTES SHEET 4 OF 4

GENERAL NOTES1 DIMENSIONS ARE PER ANSI Y-14.5 WITH MODIFICATIONS MADE TO ENABLE THE HOME BUILDER TO MORE EASILY

INTERPRET AND APPLY.

2 DIMENSIONS IN PARENTHESIS ARE REFERENCE DIMENSIONS (DO NOT USE FOR CUTTING PARTS). (CRITICAL NOTE)

3 DIMENSIONS IN BOXES ARE BASIC DIMENSIONS AND HAVE NO TOLERANCE (SEE NOTE 4).

4 ALL PARTS WITH SIMILAR HOLES AND BASIC DIMENSIONS SHOULD BE MATCH DRILLED WITH DRILL FIXTURE TO INSUREACCURATE ALIGNMENT (SEE DRILL FIXTURE DRAWING, CNC00015AUX). (CRITICAL NOTE)

5 WHEN MATCH DRILLING PARTS ALWAYS MARK SIDES WITH CORRECT DATUM LETTER AND MATCH THEM TO THE DRAWING DATUM'S WHEN ASSEMBLING. (CRITICAL NOTE)

6 ALL MANUFACTURER PART NUMBERS ARE PROVIDED AS REFERENCE AND MAY BE SUBSTITUTED WITH SUITABLEPARTS FROM OTHER SOURCES.

7 MOUNTS FOR OTHER ROTARY TOOLS AND CUTTING HEADS CAN EASILY BE MADE TO ATTACH TO THE MOUNTING PLATE (PART NO. 28) OF THIS ASSEMBLY.

8 GLUE (PART NO. -61) SHOULD BE APPLIED TO ALL WOOD PARTS AT ASSEMBLY. INSURE FLATNESS ANDPERPENDICULARITY OF ALL PARTS BEFORE CLAMPING WITH BAR CLAMPS. INSTALL STAINLESS SCREWS AFTER 10-15 MINUTES.

9 INSTALL ALL ATTACHED PARTS INTO SUB-ASSEMBLIES AS SHOWN IN ILLUSTRATIONS AND ASSEMBLY DRAWINGS.

10 AFTER ALL SUB-ASSEMBLIES ARE COMPLETE, RODS, DRIVE SCREWS AND MOTORS CAN BE ASSEMBLED.

11 WIRING INFORMATION IS SUPPLIED BY THE VENDOR OF THE DRIVER BOARD AND MOTORS. WWW.XYLOTEX.COMOR WWW.HOBBYCNC.COM ARE SOME SOURCES OF INFORMATION ON THEIR VARIOUS OPTIONS.

12 FOR WIRING LIMIT SWITCHES (FIND NO. 37) SEE YOUR DRIVER SOURCE RECOMMENDATIONS.E-STOP CONTROL BOARD FROM CNC4PC CAN BE INTEGRATED WITH THE XS-3525/8S-3 BOARD. SEE PARTS LIST OPTIONAL HARDWARE. MORE INFO AND WIRING DIAGRAM CAN BE DOWNLOADED FROM WWW.XYLOTEX.COM.

5/20/2008 CNC NOTES REVISION D 1

GENERAL NOTES13 LIMIT SWITCHES SHOULD NOT BE INSTALLED BETWEEN DRIVER AND MOTORS. THIS CAN DAMAGE THE DRIVER BOARD.

INFORMATION ON INSTALLATION CAN BE OBTAINED FROM XYLOTEX. COM AND OR DRIVER SOURCE.

14 BEARING SPACERS FN30 SHOULD NOT FIT TIGHT AGAINST RETAINING RING FN37. ALLOW .03 - .06 SPACE FOR BEARING FLOAT.

15 PRE-DRILL ALL FASTENER HOLES IN BALTIC PLYWOOD PARTS TO ROOT DIAMETER.

16 PARTS LIST ITEMS MARKED (OR EQUIVALENT) MAY BE SUBSTITUTED FOR SUITABLY SELECTED PARTS.

17 BEARINGS FN56 MAY BE EDGE WRAPPED WITH TEFLON TAPE IF NEEDED TO INSURE A SNUG FIT IN MOUNTING BLOCKS.

18 WHEN ASSEMBLING MACHINE DO NOT TIGHTEN FASTENERS FOR MOTOR MOUNTS, BEARING BLOCKS & DELRIN NUTS.AFTER THE REST OF THE MACHINE IS SOUNDLY ASSEMBLED ADJUST THE MOTORS, BEARINGS & DELRIN NUTS ASDESCRIBED IN NOTE 19 AND 20.

19 TIGHTEN BEARING BLOCK AND MOTOR MOUNT FASTENERS ONLY AFTER ALL OTHER HARDWARE IS SECURED. MOVEGANTRY TO MOTOR END OF TABLE AND TIGHTEN MOTOR MOUNT FASTENERS. THEN MOVE GANTRY TO OPPOSITEEND AND TIGHTEN BEARING BLOCK FASTENERS. REPEAT THIS PROCEDURE FOR THE HEAD & GANTRY AND THEZ AXIS & HEAD. ENSURE THAT LEADSCREW AND BEARINGS MOVE FREELY ON RODS.

20 TIGHTEN FASTENERS FOR DELRIN OR ANTI-BACKLASH NUTS ONLY AFTER ALL OTHER HARDWARE IS SECURELY TIGHTENED.

21 AFTER INSURING THAT GANTRY, HEAD AND Z AXIS ARE MOVING FREELY ON LEADSCREWS AND NOT BINDING YOU AREREADY TO CONNECT YOUR MOTORS TO THE DRIVER SYSTEM AND SET UP YOUR SOFTWARE.

22 DRAWING CNC0018AUX SHOWS ILLUSTRATIONS FOR ROUTING THE MOTOR AND TOOL WIRES AND MAKING AN ENGRAVING TABLE ADAPTER.

23 MAKE FROM Ø.50 X 30.0" LG ROUND ALUM. OR YOU CAN PURCHASE MACHINED ALUMINUM MOUNTING BLOCKS FROM EBAY SELLER Precision-CNC-Router FOR ABOUT $25.00 EACH IF YOU DO NOT WISH TO CUT AND TAP THESE PARTS.

5/20/2008 CNC NOTES REVISION D 2

LIST OF HARDWARE VENDORS

Enco www.use-enco.com 800-USE-ENCO Alum angle, drill rods, Frelon linear bearings, flanged & radial bearings, Set screw couplings, socket head cap & flat head screws, washers, nuts STURDI-BILT Workbench Legs, HDPE 1/8”, 1/2”

Precision-CNC-Router premachine2004 (eBay seller) 9”, 24” & 36” leadscrew w/Delrin nuts

Roton http://www.roton.com/ Anti-Backlash Nut, 1/2 - 10 RH Acme $33.87 \ea. Xylotex www.Xylotex.com 3 Axis Driver System Complete w/425 oz/in motors McMaster Carr Supply Co. www.mcmaster.com External retaining rings, Neoprene O-Rings Radio Shack www.radioshack.com NC Momentary switch – round push button type Mouser Electronics, Inc. www.mouser.com PacTec Encl. 72496-510-039 DM-4, Limit Switch PN101-1203 mountain type Lowes local store Screw pads, misc. hardware & fasteners Amazon.com www.amazon.com 36” T-Slot Track, Star knobs & Hold down clamps Metal Connections, Inc. metalconnections (eBay) 631-231-0087 6061-T651 aluminum plate cut to size Rockler www.rockler.com T-Track Kits, hold down clamps, Titebond

widgitmasterinc http://www.ebay.com Delrin Acme Flange Nuts 1/2-10 RH

LIST OF TOOL SOURCES

Amazon.com www.amazon.com Delta bench top Table Saw w/Legs $99 Enco www.use-enco.com 800-USE-ENCO Delta bench top Drill Press $99