Now that we have the frame assembled, its time to start working on the linear stages. We salvaged some really nice smooth rod from an old copy machine, so we decided to use that. On the first attempt, we tried to use small pieces of wood to mount the rods, but then realized that we had a bunch of thermoplastic laying around unused.
Step 1: Create Mounting Brackets
The first step was to melt some plastic. You can do this a variety of ways, but we found that a heat gun did the trick... really well. Simply put some plastic (CAPA) on your work surface and then heat it until it is transparent and goopy. We found that even when fully melted, the plastic is still pretty viscous, and pretty hard to work with. It sticks to just about anything.
Once you have a good sized chunk melted, attach the blob to the end of your smooth rod. Its not important at this stage to shape it, simply attach it. Now put the rod to the side for a couple minutes to cool, and start melting more plastic for the next rod or other end.
After a few minutes, the plastic will cool and be easy to work with, yet wont burn your fingers. Shape it so there are 2 tabs, one on each side. These will be where you drill through to attach it to the frame. Once it cools even more, lay it on something flat and hard and flatten the bottom so it will set well on the frame. After it cools completely, rotate one of the brackets so you can get them both aligned perfectly.