It all started after the package from MTW arrived...
(See last post)
This was a relatively small box, but it contained, in addition to most of our X and Z motion components, the Misumi extrusion corners I've been so interested in trying out.
I brought the box to work with me, and Tony and I wasted no time in divvying up the stuff - rods, linear bushings, etc. When Tony first saw the Misumi corners, it was apparent he'd figured out why I ordered four extras. It started him on a path of experimentation which I might pursue a bit later on, myself, after this project is up and running.
The way he tells it, he got to comparing dimensions on the upright frame members between MendelMax 1.5 and 2.0, and, finding them to be similar, decided to experiement with some printed parts from the MendelMax 2.0 to create something of a hybrid. It might be better, though, if I just show you, though, since Tony was good enough to take a couple of pictures:
Here's the side view:
and a view from the front:
An observant reader will note the use of Misumi corners at the rear of the frame. Tony was impressed with how much more rigidity the frame displayed just from using the corners to join the pieces together.
As I said, this line of experimentation has promise, but I will be pursuing a path to a more conventional MendelMax 1.5 with only a couple of minor tweaks. As this experiment continues, though, we will cover it here. Who knows? A resounding success might convince me to change my mind, but it's too early for that yet.
So... I mentioned the Y-Axis Bed Support? I dug out my lower frame assembly (which I had left sitting on a flat surface under some boxes during the long wait) and put it on the glass top of the kitchen table, fully expecting it to still have that slight twist I mentioned. Nope... all nicely flattened out. This being the case, I went ahead with installing the bed support extrusion.
It's been a while since I worked with extrusion corners, and the ones we got from MTW were cast. They're accurate enough (they checked square), but had some sprues left from casting that I took a file to and smoothed down, just for appearance's sake. (My prior experience with extrusion was with Bosch stuff - very high quality/very pricey.)
After knocking off the rough spots, I mounted the corners onto the inside of the frame, using the already trapped T-slot nuts staged for this purpose during the Lower Frame assembly, and 5 mm X 10 mm socket head cap screws.
With the corners loosely in place on the frame, I first lined up one set of corners loosely to the left side of the bed support extrusion. (It's worth noting that having the extrusion pre-cut to length accurately by Misumi was a real time saver, as it avoided any misalignment.) After this was done, I started the other set of corners on the right side, running them up loosely, also.
Now began the process of measuring and aligning the support extrusion to be square and centered in the frame. I started at the back of the frame, measuring 150mm from the centerline of the extrusion to the outer edges of the frame on each side using a good steel rule.
When I got this end in position, I began running up the screws, gently at first, and re-checking alignment as I got gradually tighter. To assure repeatability of the measurements, I checked along the entire length with the rule now clamped in a combination square attachment.
So far, so good, but as I got closer to the front end, I found I had to apply a bit of pressure to get the front end to line up with it. (There was about 1 mm worth of deflection needed to square it up.)
Rinse; repeat. Running the screws up at the front end gently, re-checking as I tightened a bit more. Now the square and rule showed good parallel measurements on both sides for the entire length.
Finally, tighten all screws and re-check. All is nice and square, true, and parallel.
Except... an almost imperceptible twist in the frame... Oh, well, back under the boxes until the slide and my upper frame mounts are ready.
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