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CNC Woodworking Shop Project The Maker

Maslow CNC Z-Axis Upgrade

Cutting parts for the “Meticulous Z-Axis”

If you look on the Maslow CNC forums, you will see that one of the greatest challenges that Maslow users face is the mechanics of the z-axis. The height adjustment on the recommended router, the Ridgid 2200, was never meant to be used in the way that it is on the Maslow. It can be altered to be OK on cuts with a limited number of z-axis moves, like furniture. But if you want to do something with a lot more depth movement, like some kinds of artwork, such as my CNC Halftone experiments or logos, it can start to get dicey. My guess is that the main issue is the accumulation of errors due to slop in the router’s height adjustment mechanism that the Maslow uses for z-axis moves (not an original idea).

3D halftone image experiment
Serifs & Whiskey logo

I should state before going into the things I’ve tried, and the recommendations I have that I am not an engineer of any kind (although my last job title before becoming a full time maker was Desktop Support Engineer). Also, if you are a Maslow user, or thinking of becoming one, you should definitely go to the Maslow forums https://forums.maslowcnc.com to get answers and advice from people who are far more experienced in this stuff than I am. My general approach to the Maslow is: I have technical skills and the Maslow is within the range of those skills, but I’m really more interested in the art I can make with it. Upgrading the machine was done out of necessity, and not because I wanted the engineering challenge. Making halftone images, for example, was something I had in mind to make from the beginning, and I did not know I’d be pushing the limits of what the Maslow can do.

There are a number of ways recommended on the forums to take the slop out of the z-axis mechanism on the Ridgid router:

  1. Add a some elastic over the top of the router and anchor it to the sled. https://forums.maslowcnc.com/t/z-axis-bungee-to-ensure-correct-depth/481 In my opinion, this should not be an option. Everyone on the forums will remind you to not put too much tension on because that might cause the router spindle to slip out of the shallow slot that connects it to the z-axis mechanism (what I learned is called a “mechanical fuse”). I have found that it is not too difficult to achieve sufficient force to take out most of the z-axis slop without causing the mechanical fuse to trip.
  2. Another easy get is putting a thin washer under the screw that the z-axis mechanism rides up and down on. https://forums.maslowcnc.com/t/cheap-fixes-for-z-axis-slop-on-the-ridgid-r22002/4031/3 The entire screw can slide a good millimeter or so, and the washer pretty much eliminates this source of slop, and it’s easy to do.
  3. Attach a bushing to the z-axis clip to keep it perpendicular to the screw. This is something that didn’t work for me and caused the mechanical fuse to trip, I suspect because I used my own solution, but I’m not sure. I suggest that if you want to go this route that you carefully follow the instructions here: https://forums.maslowcnc.com/t/cheap-fixes-for-z-axis-slop-on-the-ridgid-r22002/4031/5

The other solution to the z-axis problem is to discard the Rigid router mechanism entirely, and build a replacement one. That’ll be Part 2.

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3D Printing The Maker

3D Printed Halftone Image

3D printed halftone image from digital image to physical 3D print.

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CNC Woodworking The Maker Uncategorized

New Video: Pentaflake Tabletop Pt. 2

Finally finished part 2 of my Pentaflake Tabletop build video. I’m looking for work, so if you’re interested in me making something like this for you, contact me via the email address in the sidebar.

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CNC Woodworking The Maker Uncategorized

Pentaflake Tabletop

Sanded and Varnished

I’m still working on the video, but I wanted to get something up on HipNerd.com about finishing this project, since I already posted to social media about it.

I had more trouble with the Maslow, but finally got a good cut.

Pentaflake pattern being cut into plywood by Maslow CNC.
Pentaflake pattern being cut into plywood by Maslow CNC.

The bit was dull from the tests I ran previously, so I changed bits halfway through, then re-ran the program to clean up the hairy stuff from the dull bit. Finally, something worked in my favor, and it cleaned up well.

Before and after changing bits.
Before and after changing bits.

I sanded the insides of the cutouts by cutting up a sanding sponge, folding it over and zip-tying it to a dowel, then putting the dowel in my drill.

I cut the tabletop into a circle using a router on a jig.

Cutting the circle using a router on a jig.
Cutting the circle using a router on a jig.

I painted a coat of clear epoxy resin into the cutouts to seal, then poured the the colored epoxy using condiment dispensers.

Tabletop with Seal Coat and Colored Epoxy
Tabletop with Seal Coat and Colored Epoxy

I sanded off the excess epoxy with 80 grit sandpaper, working in sections.

Sanding in progress
Sanding in progress

I sanded everything smooth, working my way to a final 400 grit hand sanding. I put some edge banding on to hide the plywood edge. Then, I put on three coats of varnish.

Sanded and Varnished
Sanded and Varnished

I’m really happy with the way this came out, and looking forward to some more projects with my Maslow.

Categories
CNC Woodworking

Maslow CNC First Project: Pentaflake Tabletop, Test #5 (I Think?)

For test #5 (there’s been so many tests, I think this was #5) of the Pentaflake Tabletop, I modified the clip on the router with a big bushing with plenty of surface area for epoxying, and used some epoxy putty made for gluing metal to metal (JB Weld SteelStik). End result: a really solid bushing, which keeps the clip perpendicular to the z-axis screw.

Router Modification: Added a bushing to the clip on the router's z-axis control to eliminate slop.
Added a bushing to the clip on the router’s z-axis control to eliminate slop.

I modified the g-code (see Hand Editing G-Code for Better Machining), and I added a bungee over the top of the router to keep constant sideways pressure on it.

The test was a success.

Pentaflake Tabletop Test #5
Pentaflake Tabletop Test #5

The cuts are clean, no burning. And, the depth is exactly the same across the whole piece.

Categories
CNC Woodworking The Maker

Maslow CNC First Project: Pentaflake Tabletop

For my first project with the Maslow, I decided to revisit a very old project, a pentaflake tabletop. 

Maslow CNC First Project: Backyard Tabletop
Maslow CNC First Project: Backyard Tabletop

Unfortunately, I have run into some technical issues, which i must troubleshoot. You can find all the gory details here: https://forums.maslowcnc.com/t/first-project-issues-z-axis-edge-burning-bit-dulling/6809 

Categories
CNC Woodworking The Maker

Maslow CNC Pt. 1

I built a Maslow CNC. This video is part one of the build process—the electronics and assembling the frame. The Maslow is a relatively inexpensive, open source CNC kit. The kit comes with the electronics and specialty hardware, and you provide the lumber, router, and a computer (and a dust control system is a good idea, too). It’s a hanging router, much like a hanging plotter, and is capable of cutting an entire sheet of 4X8 plywood (with some margins). It can also cut thin aluminum, pretty much any material that the router you equip it with is able to cut. I’m very excited about the creative possibilities that this machine will open up for me.