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  1. Review Free CAD image
    • Review Free CAD image

  2. Lay out materials for outer frame from http://labs.nortd.com/lasersaur/bom-subs...
  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.

  4. Build second corner bracket for front of frame
    • Build second corner bracket for front of frame

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

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

  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)

  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)

  9. Build rear corner horizontal using a single bracket.
    • Build rear corner horizontal using a single bracket.

  10. Do the same on the rear left corner.
    • Do the same on the rear left corner.

  11. Install rear vertical of overall frame
    • Install rear vertical of overall frame

  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.

  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.

  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

  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.

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

  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.

  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.

  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.

  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.

  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.

  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.

  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.

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

  25. Insert the small separation panels
    • Insert the small separation panels

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

  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.

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

  28. 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.

  29. Place the gantry frame on top of the table.
    • Place the gantry frame on top of the table.

  30. 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.

  31. Place the separation panels in the frame. Place the separation panels in the frame.
    • Place the separation panels in the frame.

  32. 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.

  33. 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.

  34. 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.

    • 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.

  35. 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.

    • Insert rubber gasket in the top window edge.

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

    • Start with the spring nuts

    • Put in bracket and 2 screws.

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

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

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

    • Take off protective foil from External Connection Panel.

    • Take out corner post.

    • Mount corner post, after putting in the panel.

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

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

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

  37. 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.

  38. 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.

  39. 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.

  40. Mount the side 4040 extrusions. Mount the side 4040 extrusions. Mount the side 4040 extrusions.
    • Mount the side 4040 extrusions.

  41. Side 4040 extrusions done.
    • Side 4040 extrusions done.

  42. 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.

  43. 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.

  44. 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.

  45. 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.

  46. Cut edges out with a dremel tool.
    • Cut edges out with a dremel tool.

  47. Install on the right hand side.
    • Install on the right hand side.

  48. 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.

  49. 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.

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

  51. 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.

Finish Line

Robert Kirk

Member since: 04/28/2013

2,008 Reputation

24 Guides authored

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