How to build the OSE Lasersaur Outer Frame

Written By: Robert Kirk (and 3 other contributors)
  • Comments: 0
  • Favorites: 0

Difficulty

Moderate

Steps

64

Time Required

Suggest a time??

Sections

1

Flags

0

  1. Edit

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

  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.

    Edit

  4. Build second corner bracket for front of frame

    • Build second corner bracket for front of frame

    Edit

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

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

    Edit

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

    • Build middle rear vertical column.

    Edit

  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)

    Edit

  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)

    Edit

  9. Build rear corner horizontal using a single bracket.

    • Build rear corner horizontal using a single bracket.

    Edit

  10. Do the same on the rear left corner.

    • Do the same on the rear left corner.

    Edit

  11. Install rear vertical of overall frame

    • Install rear vertical of overall frame

    Edit

  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.

    Edit

  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.

    Edit

  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

    Edit

  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.

    Edit

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

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

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

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

    • Take out the panels, insert the table frame.

    Edit

  25. Insert the small separation panels

    • Insert the small separation panels

    Edit

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

    • Insert the large separation panels

    Edit

  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.

    Edit

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

    Edit

  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.

    Edit

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

    • Place the gantry frame on top of the table.

    Edit

  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.

    Edit

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

    • Place the separation panels in the frame.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

    • 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.

    Edit

  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.

    Edit

    • Insert rubber gasket in the top window edge.

    Edit

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

    Edit

    • Start with the spring nuts

    Edit

    • Put in bracket and 2 screws.

    Edit

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

    Edit

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

    Edit

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

    • Take off protective foil from External Connection Panel.

    Edit

    • Take out corner post.

    Edit

    • Mount corner post, after putting in the panel.

    Edit

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

    Edit

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

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

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

    • Mount the side 4040 extrusions.

    Edit

  54. Side 4040 extrusions done.

    • Side 4040 extrusions done.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  59. Cut edges out with a dremel tool.

    • Cut edges out with a dremel tool.

    Edit

  60. Install on the right hand side.

    • Install on the right hand side.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit

  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.

    Edit
Finish Line

Author

with 3 other contributors

Robert Kirk

Member since: 04/28/2013

2,008 Reputation

24 Guides authored

0 Comments

Add Comment

View Statistics:

Past 24 Hours: 0

Past 7 Days: 0

Past 30 Days: 1

All Time: 433