Extending Power Route Z Clearance

[oldtech]

I have the need to mill a 2" x 5" x 10" block. With a double mount plus a dusk collector there is not much clearance even for the 2" thick block with a 2" length bit. It is doable, but it is still a tight fit.

Removing the lower router mount and mounting to the upper mount adds another 2" travel to Z axis. So this would work for a 2" thick block.

For the 5" thick side, mounting to the upper router mount would not work. So I thinking that could 1) move the upper mounting bracket up or 2) mount an extender plate on the Z plate and then mount the router mounts to the extender plate.

I'm thinking that an extender plate would provide more Z clearance. It would allow milling 5" or taller parts that are less than 2" thick. It could also clear the motor mount for the Z plate allowing for milling parts higher than 5".

For first option I would need to drill mounting holes in the Z plate and I doubt that I can do that manually with any degree of precision. For the second option I can use the PR to mill an extender plate and attach to existing mounting holes (for rigidity I would also attach the upper part of the extender plate to the upper part of the Z plate).

Any advice? What material should be used for the extender plate? I'm thinking that it should be at least 0.5" thick. Would plywood work or should it be aluminum plate? 

It would also help if I could get the specs for the holes in Z plate.

[Derek the Admin]

On the 2" side I'm thinking there should be ample clearance unless the router was mounted really low. The absolute binding constraint if you want to traverse over the work piece will be the X plate clearance over the gantry, which is about 4.95" or so. It sounds like you have that part well understood and you are thinking in the right direction.

If it were me I'd make it from aluminum. Plywood would work if it's just a quick thing, but it won't be as good as the aluminum. I can get the bolt spacing from the office tomorrow.

[oldtech]

Thanks. The spec for the Z plate will help.

[Derek the Admin]

The top to the bottom holes are 50mm apart on center and left to right they are spaced 64.60. In other words, the bolt pattern for the mount is a 50x64.6mm rectangle.

Hope that helps.

[oldtech]

Yes. I was measuring 64.695 and 64.585 and looking for an even/whole number. It's good to know the design number.

[joebob296]

Make sure you still have the downward travel required. I just milled out a new z plate but I changed out the ball screw and rails for longer ones because I needed the extended travel.

[oldtech]

I've been thinking about adding a longer ball screw and rails. That seems like it would be a better solution. How did you fit the longer ball screw and rails? Would it not require extending the x plate upwards? What size did you change to?

[joebob296]

Yep, X plates are 2.5" taller, made from the same thickness Aluminum. It only sucked because I had to take apart one side to to get the dimensions and hole placements, then re-assemble. The Z plate was milled for a 2.2k spindle

[oldtech]

I have added a new z-plate plus a mount adapter plate to extend the Power Route z clearance. 

It allows machining up to 2" narrow parts as high as 10" while allowing for a 1.5" thick milling vice on the table. It also makes it easier to work with spoil-boards by raising the collet by 1" and to tram the router using the Edge tram tool and without having to disassemble the z-plate.

The new z-plate is about 30mm wider to accommodate attaching the mount adapter plate. It adds seven 5/16" threaded positions. I normally have it installed in position 2 to adjust the router upwards when using 3/4" spoil-board. I estimate that it will take about 10 to 15 minutes to change positions and that includes traming the router.

Next up: I'm thinking about raising the gantry clearance by 60 - 120mm and adding a longer z travel to accommodate the increased gantry clearance.

[oldtech]

I have attached a picture of the assembled mods.

Attachments:

[joebob296]

Dec 29, 2019 3:53:38 GMT oldtech said:

I tried posting a picture of assembled mods, but it looks like it did not work.

You can view the picture at: photos.google.com/direct/AF1QipNv08rYsBjwna2kOVnaqCAKlt_aUUFfslraslV_YrcGQ_-7QQIsahOMXlewZk7UDw/photo/AF1QipPJ6hUp3RS7kY95rr9KL9FoC2j4sxHFydxenl6Q

I get Error 404 Page not found.

[oldtech]

Thanks. I have edited the post and attached a picture.

[Derek the Admin]

Thanks for sharing chet.