Introduction: 3D Router: When a CNC Machine Is Overkill.

The idea arose after dealing with the difficulties and loss of time in preparing for certain CNC jobs. Sometimes I spent more time preparing for the CNC than the work itself. With this manual router, you can make holes or mill very fast. A 43mm Clamping Collar makes it very versatile and you can change the milling tool to drill very fast.

There are certainly lots of wooden router table and CNC router plans floating around in cyberspace. What makes this project noteworthy are the feature set and the cleverness of how it’s all put together and designed for maximum versatility. This router table can be used as a 3-axis drill press, sanding station, a 2D router, and you can do simple shapes 3D milling via a reference model. Using a series of accessories, you can also cut circles, straight-cut squares, and cut to a 2D reference model.

The uses of this tool are varied. I am a guitar maker and my plan consists of devising several templates of guitar bodies and necks to be made with the 3D Router, without switching on my CNC. Besides, it can also be used for other woodwork tasks. I have tried to make a design which can be easily built, with rather simple and cheap. Check out the Youtube video.

  • Overall dimensions: 800mm high, 740mm width and 700mm depth.
  • Useful dimensions: 425mm in X Axis, 535mm in Y axis and 185mm in Z axis.

What You'll Need:

  • Woodworking tools
  • A sheet of 18mm thikness plywood (2500x1250mm)
  • 32 ball bearings (608)
  • 5 Lineal meters L perfil of steel (1mm thikness)
  • 500mm steel piper, 10mm exterior diameter and 8mm inner
  • A lot of M8 and M6mm metric screw
  • A lot of M8 and M6mm Washers
  • A lot of wood screw
  • Number 23 Metal spring 140 x 22mm

You can also check out my website! www.paoson.com

Epilog Challenge:

This tool would be very useful for Luthier jobs, to engrave truss rod covers, pickguards, picks and other guitar parts, even to engrave my logo.

Youtube Video

Step 1: Designing the Project.

I have designed the project in Autocad, a 3D model which I made several construction layouts for. Plans are available on my website. Parts of the layout can be life-size printed; you can paste them on the plywood and cut, or just use the plans as a reference and then measure, as I usually do it.

Step 2: Starting the Project.

Using my homemade Router & Saw table to start this project. Making this tool requires great precision and considerable experience in woodworking. Cuts should be perfectly straight and square. They must be axis parallel and well aligned, to avoid bumps on bearings, otherwise, the tool will start vibrating.

https://www.youtube.com/watch?v=srq9sA9lfxM

Step 3: Assembling Table and X Axis.

Finish cutting, sanding and prepare all the pieces according to plans. Then, start assembling the axis metal profiles (L-shaped). They must be made of iron or steel. I've used aluminum, but, as it is softer than the bearings, a groove can be made on the metal profiles, which after long term use may cause width . You can glue it or screw it preventing the screws from touching the bearings. Use a rule to leave them paralell and straight.

https://www.youtube.com/watch?v=es6nkWRrCfY

Step 4: Finishing X Axis and Beginning Y Axis.

Once the X-Axis bench is assembled, start with the bearings of this Axis, as you can see on minute 2.45, we must enlarge the 8mm hole in the direction and areas that are marked on the plans to adjust bearings to the metal profile, to prevent width. Use dowels to reinforce some parts that require more strength.

https://www.youtube.com/watch?v=6yZo7YMXnG8

Step 5: Continue Assembling Y Axis.

When the Y axis frame is assembled, before starting with the Z axis, needless to say that this frame should be perfectly square so as to faultlessly slide along the arms of the X axis. So far, we have done most of the work!

https://www.youtube.com/watch?v=3qS4HVTwCD8

Step 6: Finishing Y Axis.

Assemble the bearings that go along the Y axis frame and test the Z-axis bearings before mounting this part on the machine. Cut and test the Z axis spring.

https://www.youtube.com/watch?v=C27xt1JFRi0

Step 7: Starting Z Axis.

Continue with the Z axis, assembling all parts. The 43mm Clamping Collar should be very exact, do it with the right drill bit or a CNC. Make sure the milling machine is well fastened because it might come off with the vibration.

https://www.youtube.com/watch?v=a8Hxy83jzKM

Step 8: Assembling Z Axis and Accessories.

End the Z axis with the actuating lever and other accessories such us the elevator control, fast clamping sleeves and the axis brakes, whish are also made from 18mm plywood. We must also finish the guideway and the worktable.

https://www.youtube.com/watch?v=caS1N_kuu2M

Step 9: Ending Z Axis, 2-3D Followers and Circles Follower.

This is the end of the 3D Router project. Finish the Z axis and the 2 and 3D followers. The parts that fasten these followers must be very firm and secure. Use glue and screws.

https://www.youtube.com/watch?v=ae8Lgmv_slw

Step 10: Electric Guitar Body on the 3D Router (part1)

Before starting this project, I install a block on the Z axis in order to mill from the rear, without having to pull the lever, which is very useful for certain pieces of work with the 2D Follower. I made the templates in a CNC for the 2D contours y for the 3D top of the guitar. If you do not have a CNC, I recommend that you order them from someone who has them. They could also be made by hand but, if it is done accurately, some good templates may be used to duplicate a job at any time! In this situation, we could also use a real guitar as a template. I made two bases of 700x350x10mm on MDF in order to hold and locate the pieces to be worked on.

Step 11: Electric Guitar Body on the 3D Router (part2)

The bearing of the 2D Follower must have the same diameter as the router bit, or install a smaller bearing if you are looking for a bigger milling cutter than the one in the template itself. The depth of each pass on Z axis depends on the material and the work tool. As you can see in the video at 2'50 min, the 2D Follower can be used from ahead or from the back. Personally, I prefer from the back because I feel more at ease with the template.

Step 12: Electric Guitar Body on the 3D Router (part3)

I lower all the elements of the Y axis, bringing the milling cutter close to the piece to be worked on. Then, I adjust the height of the touch probe in order to use the 3D Follower. As I am going to lower the cover by passing several times on Z, I first leave the milling cutter at a slightly higher level than the touch probe. In the last pass, these heights must be identical. As with the 2D Follower, I prefer milling from the back because I feel more at ease with the template and it is less dangerous.

Comments

author
RockerTony (author)2015-09-03

Sir, you are a fargin' genius! You're not just a guitar builder you are a full blown certified mechanical whiz-bang engineer! I build guitar amps 'cause I'm good at electronics, but suck at woodwork, which is why all my builds are in a prefabbed metal cage, like a lunchbox type amp. I don't think I could build this even with all your drawings. I am jealous of your talent! ;-) Oh yeah, and I voted for you!

Tony_on_the_Mic-400.jpguber_pic.jpg
author
fitz.pock (author)RockerTony2015-09-13

I couldn't have said it better than RockerTony, and I don't even know what fargin means. What an awesome project, Paoson. Hope you get hired as a consultant at a major tool company, and next year we will all be able to buy one at Home Depot!

author

Ohh, beautiful, you're a genius with electronics, thank you!

author
bigbigdave (author)2015-09-03

This is absolutely amazing! Really great work - great design, great execution.

author
bigbigdave (author)bigbigdave2015-09-03

PS - To my fellow Instructablees, sitting mouth-agape after seeing this, make sure to vote in the upper right corner. I don't care what contest this is in the running for, it should win, IMHO.

author

Thanks friend!

author
alcurb (author)2015-09-02

Excellent project. I only wish you had provided the plans at no cost.

author
Gartholameau (author)2015-09-01

Incredible! Can I have one of the 50 prototypes you made before coming up with this final mechanical marvel? :-) This is beyond impressive and is well into the realm of wood art.

author
comitrago (author)2015-09-01

fantastico, voy a tener que hacerlo, eres un genio

author
lkndave (author)2015-09-01

what format are the plan files in?

author
Paoson Woodwork (author)lkndave2015-09-01

A 3D Model in Autocad ans Sckethup, and a lot of Pdf files.

author
lkndave (author)Paoson Woodwork2015-09-01

thanks, i ordered your plans before you replied. i guess when you send them i'll see what i can do with them. thanks again

author
mahdmod.musafani (author)2015-08-31

What a nice solution for many basic workshop tasks! I have to build similar gizmo out of alu extrusions! I built a small CNC but there it just stands collecting dust... This is the way to go!

author

Thanks a lot!

author
Phil_S (author)2015-09-01

Very nice.

Arms work just as well as steppers, nice use of bearings and angle profiles.

Must have taken a few hours with pencil and paper - but, please mind the MDF dust and some ear plugs wouldn't go amiss. An old vacuum cleaner rigged up on a rope from the ceiling would keep a clean and safe bench.

Otherwise, 5-stars for ingenuity and bringing it to completion.

author
Paoson Woodwork (author)Phil_S2015-09-01

It's true, I'm working on it, thanks!

author
slysimon (author)2015-09-01

Simply amazing. So many uses. Fantastic little machine. Many, many thanks for the 'ble.

author
Paoson Woodwork (author)slysimon2015-09-01

Thanks...

author
sosclosetsandfurniture (author)2015-09-01

Well you are awesome! That is the most clever thing I have seen! Great job!

author

Thanks friend!

author
larystoy (author)2015-09-01

I have been searching for this concept for months; it is so
good I saved it in a folder called "3-D_router_must_make". I don't
care what the cost; I MUST have the plans for this tool. It will do so many
things and is so much more economical compared to a CNC machine.

author
Paoson Woodwork (author)larystoy2015-09-01

Thanks!

author
Garadin (author)2015-08-28

This is the most amazing thing I have ever seen. Ever.

author
rickharris (author)2015-08-28

Epic. First class out of the box thinking.

author
tomatoskins (author)2015-08-28

Oh my goodness! That's one beautiful piece of machinerey!

author
shcho (author)2017-05-04

Thank you~~ your ability is really impressive me~~

author
egallet (author)2017-03-12

I had a fellow,coworker I needed to ask a question. He always wanted to go into details which I really didn't need to know and time was short. When He started, I politely told him..ok I in essence don't need to know the theory of aerodymics, I just need to know what time to be at the airport. He grinned and I got the answer. You sir have gotten that down. ?

author

What do you think the prospects are on adapting the design to fit a more common router motor? Like one of the Bosch or DeWalt heavy duty compact routers.

author

It is possible, take a look to this article:

http://paoson.com/downloads/blog/3d-router-reader-n47

author
Yonatan24 (author)2016-08-11

Hi, I've added your project to "The Ultimate Collection of DIY Workshop Tools" Collection

Here is the link If you are interested:

https://www.instructables.com/id/The-Ultimate-Colle...

author
Hansik13 (author)2016-06-16

Man u r genius!!! I love it and im try to make it.

author
ShontaLatteyz (author)2016-04-07

You are amazing man! Great design and easy to build. I can't afford your 15euro plan and i dont have a table saw, band saw, etc. i dont even have an electric drill. I will make one with just a chisel, hammer, saw and monkey wrench. This will take me years to finish but i am very determined. :) -your youtube follower from cebu, philippines

author
nkhalsa (author)2016-03-02

Jack Cox's Pivot Frame Jig, sold by Trend, is a much less expensive
approach, but suitable only for lighter jobs. I use it for grounding my
relief carvings.

author
bjenkins10 (author)2016-02-02

this is incredible. no other word to describe it

author

thank you!

author
gana_anaq2 (author)2015-11-29

this is exactly what i wish for 2 years, it suits all my needs and dreams about the tool. I would add callipers on each axis for better control .

On this device i saw a problem that is ommited to be shown: Accuracy

If you look in detail at the movies, you will remark how much all the x axis is wobbling.

To avoid this i plan to use rail bearings on the axis for a lot extra cost, and then i am sure that i will remark sensitive axis play because of the plywood elasticity so ... my advice for those that plan to build it is to make a wood sample of it, with linear bearings like ( bosch rexroth ,NSK) , and then if accuracy is not satisfied, review the current layout and improuvements and then order aluminium ( adodized or not) parts to a shop machinist and will result a 24/24 work hour machine

author

Yeah, If you can afford it, That's the best solution. But only if you need a so high
accuracy. If you have that budget you may also could think in a V-groove bearings solution or even make the whole thing in aluminum. Your choice ;) Thanks for comment!

author
bricabracwizard (author)2015-11-22

Well done for making the finalists in the Epilog contest! I hope you win!

author
Daniel113 (author)2015-11-07

I
love your videos. Very educational. I’m 59 years young and have been working
with wood since (I was) 10 to 12 years old, but never had anyone to educate me.
Then, thanks to computers, I can (now) learn something right. It’s a shame to
see that some (of these) experiences will never be passed on to the younger
gen. You can see some tips at my blog below:

http://woodworkingbuddy.com/

author

Nice blog, thanks!

author
Paoson Woodwork (author)2015-11-11

WOW! Awesome dude, I love how Miller looks and the mods you made. May I ask you for permission to use your images for a new entry in my blog?

Congratulations for Miller, It looks amazing!

author

No problema!

author
bricabracwizard (author)2015-11-08

I have come up with a different idea on how to make a follower which will also allow me to do ovals and invert 3D objects...this will take a couple of months before I complete this....other priorities at the moment.

author
Darkjay007 (author)2015-10-19

What an Amazing project!
I am very interested to buy your plans, but before i need to know how does it cost to build one.
1/ for the 3D router
2/ and also for the router and saw table.
If it's thousands of dollars it will be difficult for me :(
3/ And at last, wich tools did you used...
If i need to buy new tools i will cry (and scream...)
Thank you
(Sorry if my english is not that good... I'm french ;-))

author
Aug308 (author)2015-10-11

I wish tool companies would apply the same ingenious designs to use tool stands like this instructable in their product lines. Simply awesome design and use of home tools to get their best uses. Will be building this soon and see multiple uses for this design. Fantastic design and excellent construction thanks

author
DarrylGF (author)2015-09-03

Yes, he has a realy nice home made easy to operate router wood working machine. I actually signed up to go Pro so I could down load the plans. Well, come to find out you need to purchase the plans for around $16 U.S. OK , I thought sure I can do that but one big hurdle. Paoson Luthier is asking way to much personal information, like Name, Address, Date of Birth. He should only have to ask for my PayPal account #, nothing else. (Which is all he will accept for payment). With all that pertinent information he could set up a PayPal account using my data and then I would most likely get all his bills. I never have heard of such a thing in my nearly 35-40 years of being on the internet. It is a wonder that he did not ask for my social security account.

And to top it off, I tried to contact Instructables and you get nowhere. Even the credit card Co. has a 510 area code + number and what does that get you, a voice mail to go to the web and type in Service@instructables.com. Which in turn gets you no where.

author
amberrayh (author)DarrylGF2015-10-07

Hi DarrylGF,

Please check your email for a response from Instructables HQ. Thank you for being a part of our community!

author
HHOSteam (author)2015-09-22

Outstanding work!
I think I've found my next project!

author
Paoson Woodwork (author)HHOSteam2015-09-23

thanks!

About This Instructable

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Bio: My name is Suso Caamanho. I like doing all sorts of stuff related to musical instruments, woodworking, computer science, electronics... On my website you will ... More »
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