Author Topic: Router sled with 80-20  (Read 2590 times)

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Offline Slartibartfass

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Router sled with 80-20
« on: December 29, 2017, 01:49 PM »
I thought why not....? After some strong Google-Fu found the following inspiration: http://www.woodworkingtalk.com/f2/8020-aluminum-79713/#post793169

Using 2x 48” long 80-20 profiles (1515-ULS) as base attached with bolt to MFT/3.

Ordered 1530-ULS profiles. The inner opening will be 93”x36”.





Turning the wheels for the router sled so they run in the slot of the 80-20 profile (Happy that I have the Sherline lathe (and mill.....).







All done:




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Offline talk-tools

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Re: Router sled with 80-20
« Reply #1 on: January 02, 2018, 01:36 PM »
Looks great so far. Curious how smoothly and accurately it will run when complete. Keep us posted!

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #2 on: January 02, 2018, 01:45 PM »
Looks great so far. Curious how smoothly and accurately it will run when complete. Keep us posted!

It is going to be bit trial and error.... Still trying to figure out how and where to attach wheels.....

After I assemble the frame things will get clearer.....

Wheels run on bearings so I am hopeful this will be smooth sailing.....

Offline grobkuschelig

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Re: Router sled with 80-20
« Reply #3 on: January 02, 2018, 02:43 PM »
You have the colors down. ;)

I can’t wait to see the further progress of this build! Great work!

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #4 on: January 11, 2018, 08:30 AM »
Getting my 80-20 profiles tomorrow.

In the interim was noodling around with the wheel connection and I think have found a way. Pictures forthcoming...

Might also consider swapping the wheels out for linear bearings in the future....

After I have both frames assembled i can figure out the tolerances and router attachment etc.....

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #5 on: January 11, 2018, 08:42 AM »
Wheel hardware:

Those bronze bushings will be pressed in on the wheel side of the profile to give additional support for the bolt/wheel. I drilled a “hole” in the area with 3/8 drill bit, the OD of the bushing is 0.38”.






Online Cheese

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Re: Router sled with 80-20
« Reply #6 on: January 11, 2018, 09:36 AM »
Those bronze bushings will be pressed in on the wheel side of the profile to give additional support for the bolt/wheel. I drilled a “hole” in the area with 3/8 drill bit, the OD of the bushing is 0.38”.

FWIW...a .375" diameter drill will usually drill a larger hole than .375". So take a scrap of the profile you intend to use and drill the 3/8" hole in it. Check how it fits with the sintered bronze bushings. You may luck out. [smile]

The typical method to install sintered bronze (Oilite) bushings is to drill an undersized hole and then ream it to the proper fit, usually around .0005" smaller than the bushing OD. Also don't hammer in the bushings as they can distort, rather press the bushings in using a stepped mandrel.  [2cents]
« Last Edit: January 11, 2018, 09:39 AM by Cheese »

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #7 on: January 13, 2018, 09:02 PM »
Got my 80/20 delivered yesterday and started to put everything together:

Main frame assembly



Corner brackets



Other parts






Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #8 on: January 13, 2018, 09:04 PM »
Router Sled Moving frame (pre-fit):












Offline jpmeunier

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Re: Router sled with 80-20
« Reply #9 on: January 13, 2018, 09:14 PM »
 Why don't you want to use their linear rails?

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #10 on: January 13, 2018, 09:15 PM »
Router Sled Moving Frame assembly:

Drilling the holes for wheel bolts







Slightly enlargement for bronze bushing



Template to locate position for drill



Hardware for wheel installation





Runs nice and smooth, no loose fit. Tracks parallel.





Flipped sled over to lower sled.



Will change corner brackets to 2 hole per side to gain more movement for router sled.


Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #11 on: January 13, 2018, 09:18 PM »
Why don't you want to use their linear rails?

Right now cost, but am considering it.... also this way it is easier to take apart and I can flip over the router sled for a different height (see last pictures in prior post)

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #12 on: January 13, 2018, 09:54 PM »
Router sled assembly itself. Wheels attach to top hole on hanging bracket. Needed to enlarge hole for bronze bushing.





Later I switched the large washer to the outside. Washer was necessary as the bronze bushing was slightly to long to bolt down properly.




Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #13 on: January 13, 2018, 10:00 PM »
Had to file off some metal for proper fit of adjoining brackets so the brackets are square to base and wheels run true.





Temporary base to check fit




Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #14 on: January 13, 2018, 10:03 PM »
I bought a piece of 1/4 thick aluminum as the router base.



Figuring out dimensions for plate



Cutting plate to size


Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #15 on: January 13, 2018, 10:06 PM »
Cleaning burrs



Drilling holes for M6 screws to hold router and countersink holes



Router attached



Used hole saw to cut opening to match router base...drilled proper pilot hole first.










Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #16 on: January 13, 2018, 10:16 PM »
Installing brackets to base with the same 5/16-18 bolts. Drill and tap holes.









FINISHED!






Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #17 on: January 14, 2018, 09:33 AM »
Still trying to figure out how to make the router plate smaller to gain more travel. Need to calculate workable area.

Offline rvieceli

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Re: Router sled with 80-20
« Reply #18 on: January 14, 2018, 09:54 AM »
@Slartibartfass consider installing the plate on top of the angle brackets in the same way you have them mounted now.. That would allow you to push them inward towards the center because the brackets would not be in the way of the router base. giving you some additional travel side to side.

Another option would be to use pieces of thicker plate for your carriage side pieces instead of the angles. Drill and tap the plate edge and bolt the bottom to the sides.

Ron

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #19 on: January 14, 2018, 10:41 AM »
@Slartibartfass consider installing the plate on top of the angle brackets in the same way you have them mounted now.. That would allow you to push them inward towards the center because the brackets would not be in the way of the router base. giving you some additional travel side to side.

Another option would be to use pieces of thicker plate for your carriage side pieces instead of the angles. Drill and tap the plate edge and bolt the bottom to the sides.

Ron

I like your second idea.....

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #20 on: January 14, 2018, 11:47 AM »
I took some measurements as to travel range of the router sled and right now it is ~ 17”. With changing the corner brackets to 2 hole vs 4 hole I gain another 3” overall.

And with changing the side brackets as recommended by @rvieceli I gain another 3” to ~23” overall.

I centered the frame over the table. In order to use the full width of the table you need roughly the setup/size that I chose...




Offline bnaboatbuilder

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Re: Router sled with 80-20
« Reply #21 on: January 14, 2018, 02:58 PM »
At this point you have the frame of a CNC. Might as well add some stepper motors or small DC geared down indunction motors which can be controlled by basic dial control, use one with a cable pulling back and forth for the router and another motor that moves the sled down the length at intervals. No need to slave away manually moving a router with how much cost and time you have put into this.

This is about as fancy as a router sled needs to be: http://www.instructables.com/id/Plane-your-wood-slabs-with-a-Planing-Sled-that-you/

Since you have gone the extra mile, extra 100 miles, might as well add the little bit of automation.
« Last Edit: January 14, 2018, 03:07 PM by bnaboatbuilder »
- John

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #22 on: January 14, 2018, 03:31 PM »
At this point you have the frame of a CNC. Might as well add some stepper motors or small DC geared down indunction motors which can be controlled by basic dial control, use one with a cable pulling back and forth for the router and another motor that moves the sled down the length at intervals. No need to slave away manually moving a router with how much cost and time you have put into this.

This is about as fancy as a router sled needs to be: http://www.instructables.com/id/Plane-your-wood-slabs-with-a-Planing-Sled-that-you/

Since you have gone the extra mile, extra 100 miles, might as well add the little bit of automation.

 ;D

That thought actually crossed my mind..... Maybe one day.....

Online Cheese

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Re: Router sled with 80-20
« Reply #23 on: January 15, 2018, 10:05 AM »
Looks good...[thumbs up] and Ron's 2nd option is also a winner. Just use 5/16" or 3/8" plate to replace the L brackets with screws from the underside of the 1/4" thick router plate.

Offline lambeater

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Re: Router sled with 80-20
« Reply #24 on: January 15, 2018, 11:22 AM »
looks awesome, love 8020. You could also put wheels under so theres no chance of lifting (just a thought).

Lambeater

Offline Michael Kellough

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Re: Router sled with 80-20
« Reply #25 on: January 15, 2018, 12:15 PM »
Very nice rig and it could be motorized pretty simply with a gear motor and limit switches.

After all this you will want to add some way to fine tune the pitch of the plate to avoid leaving a little ridge every lap.


Offline bnaboatbuilder

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Re: Router sled with 80-20
« Reply #26 on: January 15, 2018, 12:21 PM »
Router planing with a wide bowl bit is much better at reducing the ridging than a flat surfacing bit.
- John

Offline Slartibartfass

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Re: Router sled with 80-20
« Reply #27 on: January 15, 2018, 12:37 PM »
looks awesome, love 8020. You could also put wheels under so theres no chance of lifting (just a thought).

Lambeater

If I would go the CNC router that would be necessary although at that point I would convert to linear bearings...

Offline rst

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Re: Router sled with 80-20
« Reply #28 on: January 15, 2018, 05:09 PM »
I had no problem with ridging with my setup using the widest planning bit I could get into the 1400, 1" I think.  Going to use my 2200 next time with Amana 2 3/8" CNC spoilboard bit I got from Toolsonsale.