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I've been threatening to build a much bigger router than my old one for years. I got laid off right before Christmas, so this was the perfect opportunity. I start a new job Monday the 14th so I'm glad I got as far as I have. It's down to assembly mostly now. I designed this one in Solidworks. I'm using a 2.2kw water-cooled ER20 spindle and a Gecko G540 to drive it with twin 340 oz NEMA 23's on the Y, and 300 oz motors on X and Z. THK 20mm rails on Y and 15mm Hiwins on the X and Z. I added two dsub9's to the back of the control box, one for VFD and one for estop and limits. The 110vac output is relay-triggered to turn on my spindle water pump. I figured I'd build two identical control boxes and sell one - all it will need is the G540.

Travel is 48.5 x 33 x 6.5. I used my junky old little router to center drill hole positions for all of my plates and then hand-drilled and tapped everything. I'm glad that part is done. I hope to have it running in a month or so. Now that I'm going back to work (CNC programmer/mechanical designer), I'll have to slow down a bit. I'm also taking a couple classes, so time will become constrained.

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Mike
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Looks like you are seeing some progress. That should be a good heavy machine.
 
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