How to build the OSE Lasersaur Outer Frame

Written By: Robert Kirk (and 3 other contributors)
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Difficulty

Moderate

Steps

64

Time Required

Suggest a time??

Sections

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  1. Edit

  2. Lay out materials for outer frame from http://labs.nortd.com/lasersaur/bom-subs...
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  3. Preassemble corner pieces, 2 mirror images Use 3 double brackets. Until the very end, leave all connections loose.

    • Preassemble corner pieces, 2 mirror images Use 3 double brackets. Until the very end, leave all connections loose.

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  4. Build second corner bracket for front of frame

    • Build second corner bracket for front of frame

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  5. Build middle vertical column, front, use 2 brackets.

    • Build middle vertical column, front, use 2 brackets.

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  6. Build middle rear vertical column. Build middle rear vertical column.

    • Build middle rear vertical column.

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  7. Build rear 3rd corner vertical. Use 2 double and one single bracket. (note later time)

    • Build rear 3rd corner vertical. Use 2 double and one single bracket. (note later time)

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  8. Build 4th rear corner vertical. (second pix at same time as last)

    • Build 4th rear corner vertical. (second pix at same time as last)

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  9. Build rear corner horizontal using a single bracket.

    • Build rear corner horizontal using a single bracket.

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  10. Do the same on the rear left corner.

    • Do the same on the rear left corner.

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  11. Install rear vertical of overall frame

    • Install rear vertical of overall frame

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  12. Install single bracket for rear left vertical, and rear right vertical. Install single bracket for rear left vertical, and rear right vertical.

    • Install single bracket for rear left vertical, and rear right vertical.

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  13. Install single bracket on right front cutting chamber horizontals. Install single bracket on right front cutting chamber horizontals.

    • Install single bracket on right front cutting chamber horizontals.

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  14. Install middle black supports on the floor of the frame, using single black brackets, 1 per meeting point Install middle black supports on the floor of the frame, using single black brackets, 1 per meeting point

    • Install middle black supports on the floor of the frame, using single black brackets, 1 per meeting point

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  15. Install 3 short 2040 extrusions on the rear base of the frame.

    • Install 3 short 2040 extrusions on the rear base of the frame.

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  16. Tighten down all joints. Insert spring nuts as needed.

    • Tighten down all joints. Insert spring nuts as needed.

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  17. Inner distance between extrusions for the front compartment should be 86 cm.

    • Inner distance between extrusions for the front compartment should be 86 cm.

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  18. Space between front horizontal and mid horizontal should be 41 cm on the inside.

    • Space between front horizontal and mid horizontal should be 41 cm on the inside.

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  19. Use the small polycarbonate separation panel - mark a .6x.6 cm corner cut out.

    • Use the small polycarbonate separation panel - mark a .6x.6 cm corner cut out.

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  20. Cut the corner out with a dremel tool. The corner cutout allows the panel to fit against the walls of the frame.

    • Cut the corner out with a dremel tool. The corner cutout allows the panel to fit against the walls of the frame.

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  21. Do the same for the second of the same panel. Do the same for the second of the same panel.

    • Do the same for the second of the same panel.

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  22. Peel the protective covering from the small panel, and insert. Peel the protective covering from the small panel, and insert.

    • Peel the protective covering from the small panel, and insert.

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  23. Peel the protective covering from the long panel, and insert. Peel the protective covering from the long panel, and insert.

    • Peel the protective covering from the long panel, and insert.

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  24. Take out the panels, insert the table frame.

    • Take out the panels, insert the table frame.

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  25. Insert the small separation panels

    • Insert the small separation panels

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  26. Insert the large separation panels Insert the large separation panels

    • Insert the large separation panels

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  27. Measure for parallel of the front and back. Also measure the diagonals to check that they are within 2 mm.

    • Measure for parallel of the front and back. Also measure the diagonals to check that they are within 2 mm.

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    • Mount the base brackets of table to the outer frame - both for the front and back side of the table.

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  29. CHECK Mount the middle rear vertical to the outer frame. CHECK Mount the middle rear vertical to the outer frame. CHECK Mount the middle rear vertical to the outer frame.

    • CHECK Mount the middle rear vertical to the outer frame.

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  30. Place the gantry frame on top of the table.

    • Place the gantry frame on top of the table.

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  31. Cut out the upper corner of the small separation panel, for both panels.

    • Cut out the upper corner of the small separation panel, for both panels.

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  32. Place the separation panels in the frame. Place the separation panels in the frame.

    • Place the separation panels in the frame.

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  33. Measure the diagonal of the gantry frame to see that it's square.

    • Measure the diagonal of the gantry frame to see that it's square.

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  34. xxxThen tighten down the 3 more single brackets in the front and in the rear. Tighten down the gantry frame to the bottom outer frame. Start with the 4 corners.

    • xxxThen tighten down the 3 more single brackets in the front and in the rear.

    • Tighten down the gantry frame to the bottom outer frame. Start with the 4 corners.

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  35. Tighten down the gantry frame to the bottom outer frame. Start with the 4 corners.

    • Tighten down the gantry frame to the bottom outer frame. Start with the 4 corners.

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    • Cut rubber gasket to size for the long separator windows - 2 seams on top and bottom horizontals. See example of how the rubber gasket fits in the grooves of the aluminum extrusion.

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  37. Insert rubber gasket in the bottom window edge. Poke in with the blunt end of a pen or some other object that helps the rubber to be pushed in the groove to create a tight seal. Insert rubber gasket in the bottom window edge. Poke in with the blunt end of a pen or some other object that helps the rubber to be pushed in the groove to create a tight seal.

    • Insert rubber gasket in the bottom window edge. Poke in with the blunt end of a pen or some other object that helps the rubber to be pushed in the groove to create a tight seal.

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    • Insert rubber gasket in the top window edge.

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    • Insert small vertical support, a 4080 extrusion - rear post for the door.

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    • Start with the spring nuts

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    • Put in bracket and 2 screws.

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    • Put in 2 remaining screws. Repeat for the second vertical support.

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    • Continue to the 4040 extrusion for the front post of the door.

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    • (These steps should be done before corner post being put in)

    • Take off protective foil from External Connection Panel.

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    • Take out corner post.

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    • Mount corner post, after putting in the panel.

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    • Mount the 2 front corner posts on top of the gantry frame.

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    • Mount the middle rear support on top of the gantry frame, using a flat bracket (10:43)

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  49. Mount side extrusion above the External Connection Panel, using 2 single brackets.

    • Mount side extrusion above the External Connection Panel, using 2 single brackets.

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  50. Mount double brackket on top of 2 corner posts. Mount double brackket on top of 2 corner posts.

    • Mount double brackket on top of 2 corner posts.

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  51. Mount top flat bracket on top of middle rear surrport above the gantry frame.

    • Mount top flat bracket on top of middle rear surrport above the gantry frame.

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  52. Mount rear horizontal, 2040 extrusion with 2 double brackets, and then mount the midpoint with a single bracket. Mount rear horizontal, 2040 extrusion with 2 double brackets, and then mount the midpoint with a single bracket. Mount rear horizontal, 2040 extrusion with 2 double brackets, and then mount the midpoint with a single bracket.

    • Mount rear horizontal, 2040 extrusion with 2 double brackets, and then mount the midpoint with a single bracket.

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  53. Mount the side 4040 extrusions. Mount the side 4040 extrusions. Mount the side 4040 extrusions.

    • Mount the side 4040 extrusions.

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  54. Side 4040 extrusions done.

    • Side 4040 extrusions done.

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  55. Mount 2040 extrusion - the mid support at the rear of the frame. Mount 2040 extrusion - the mid support at the rear of the frame.

    • Mount 2040 extrusion - the mid support at the rear of the frame.

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  56. Mount 4040 extrusion for the rear of the cutting chamber - using 2 double brackets at the sides and a double planar bracket in the middle. Mount 4040 extrusion for the rear of the cutting chamber - using 2 double brackets at the sides and a double planar bracket in the middle. Mount 4040 extrusion for the rear of the cutting chamber - using 2 double brackets at the sides and a double planar bracket in the middle.

    • Mount 4040 extrusion for the rear of the cutting chamber - using 2 double brackets at the sides and a double planar bracket in the middle.

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  57. Use small bolts (8 mm long) and a washer for the flat double bracket. Before fixing this rear post in place, we need to install the back separator window.

    • Use small bolts (8 mm long) and a washer for the flat double bracket. Before fixing this rear post in place, we need to install the back separator window.

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  58. Take the rear window and peel the protective cover. Take the rear window and peel the protective cover.

    • Take the rear window and peel the protective cover.

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  59. Cut edges out with a dremel tool.

    • Cut edges out with a dremel tool.

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  60. Install on the right hand side.

    • Install on the right hand side.

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  61. For the second panel, cut edges with dremel tool and then drill out a 16 mm hole, in location as shown. For the second panel, cut edges with dremel tool and then drill out a 16 mm hole, in location as shown. For the second panel, cut edges with dremel tool and then drill out a 16 mm hole, in location as shown.

    • For the second panel, cut edges with dremel tool and then drill out a 16 mm hole, in location as shown.

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  62. Put in upper rear windows and close off with 4040 extrusion on top. Put in upper rear windows and close off with 4040 extrusion on top.

    • Put in upper rear windows and close off with 4040 extrusion on top.

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  63. Cut rubber gaskets and put them in the side external connection window.

    • Cut rubber gaskets and put them in the side external connection window.

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  64. Finish putting in rubber gaskets - on the 2 horizontals in each window - for the 2 upper windows.

    • Finish putting in rubber gaskets - on the 2 horizontals in each window - for the 2 upper windows.

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Finish Line

Author

with 3 other contributors

Robert Kirk

Member since: 04/28/2013

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