Update:
I am back to work on this build following moving from CA to WA and setting up my shop. I also have been an instructor at the Bainbridge Barn- a 20000 square feet 11 studio non profit facility and have only recently got around to my personal stuff. The place is pretty awesome:
Welcome to BARN (Bainbridge Artisan Resource Network) - BARN
I am nearly done with the base. It is ¼” thick 2” square tubing will have ¼” plate on the top and all sides. It is 23” by 44”. It seems pretty stout but I may cast epoxy granite into it to add mass as I am concerned the machine may move during rapids:
Here is rough draft of the design so far. I am still working on the head and tool changer mounting:
Over the past 2 years, I was able to purchase of all linear motion components for the machine. Even shopping for deals, this proved to be a significant investment with the large sizes being used:
THK SHS 35mm linear rails with 6 blocks for x axis 42"
NSK 35mm linear rails and blocks for y axis 36"
THK SHS 30mm linear rails and blocks for z axis 30"
Here is a pic. Keep in mind the base underneath is 44” long:
For ballscrews, I went with giant 36-45mm ground ball screws from THK or PMI(new replacement for a HAAS) all around.
Given the linear motion parts I ended up getting, the travels will be slightly different with the x axis being 25" in travel.
I was able to get a 300 lb scrap piece of steel for $100(!!!) to make the bearing blocks. It is 3" thick. Moving it and cutting was interesting!
Here is the design for the bearing blocks. It matches the 4" holes with coupling nuts I cast in place on the mill's base. 4" x 5" x 3" thick:
Angular contact bearing showed up while I was cutting. They are 3 bearing matched sets:
I was able to partially finish the shear panels on the machine's sub-base and got the front and back one's welded on. Did a test fit of the base on the sub base and it is really solid. I am really happy with the height. By the time you add the saddle and table, It should be right. Hope to start work on the saddle mold next.
Here are a few pics of the test fit: