How to make a mini milling machine- manual or CNC!

Step 3 Make the slides

For this step you'll need a router table- if you don't have one you can make one by screwing (or securely clamping) a 5/8" or 3/4" thick piece of MDF to a bench top. Bore a hole in it using a hole saw and mount your router from the underside (see drawing). Use a piece of MDF or plywood to make a fence by clamping it on each side of the table. The 1/2" straight router bit should just barely touch the fence.

Now take the three 4" x 3 7/8" Delrin pieces and cut a shallow track into the bottom of the 4" long end on both sides. The depth of the cut should match the wall thickness of the Aluminum channel exactly.

When assembling the mill, if you find that the slides bind on the Aluminum channel you can go back and adjust the fit by trimming the width of the track you just cut. This can be easily accomplished by loosening the fence, slide it away from the 1/2" router bit and sliding a piece of typing paper between the fence and the bit. Now clamp the fence down and remove the sheet of paper. This will allow you to cut a few thousandths of an inch off the Delrin slide at a time, enabling you to adjust the fit of the parts and get the slide to operate smoothly.

Comments

[kharmsengine]

Oops, just noticed they aren't slots, but the question basically remains the same.

[Honus]

A table saw will cut Delrin just fine- I use mine to cut Delrin all the time.

[kharmsengine]

Excellent! Thank you.

[kharmsengine]

I would really like to build this, especially being that I already have some of the materials. Unfortunately, I don't have a router. Have you ever tried cutting the slots (dadoes) in Delrin with a table saw?
Thank you for one of the best instructables I've ever seen!

[steverichardson]

wow thanks

[derek_eide]

I haven't had the chance to look through all of this in detail but from what I've seen I have to say you are an artist.

[Honus]

Thank you very much!