Re: [CAD_CAM_EDM_DRO] Levelling large table

No router table experience, but some experience in some of the suggested
ideas:

1. Even the low viscosity epoxy won't provide a level surface. As the
epoxy cures it will shrink towards the middle.
The "meniscus due to adhesion between the liquid and the sides of the mold
will cause the edges to be raised somewhat...just like in a glass of water.
The center area will have slight waves and possibly indentations due to air
bubbles bursting as the material cures.

2. Jack screws will help...but only if you add some cross beam supports
under the table and run the jack screws thru these members (or to thru some
brackets connected to them). Jack screws can be found on the table insert
for supporting the router on some router table.

Using a rotary laser level in combination with the jack screws might help.

3. If you want to cut the aluminum plate with the router head, be advised
the best flatness will occur when you machine BOTH sides of the
plate..UNLESS you have the plate stress relieved first. Due to
manufacturing processes, stresses are induced in metal products. Machining
one side of the plate will remove the stresses on the side machined and the
reemaining stresses on the other side will cause the plate to warp. It is
best to machine some of each side and then repeat the process to obtain the
greatest stress free and flat part. This is probably (one of the reasons)
why those other manufacturers use phenolic rather than aluminum.




Another problem you'll run into with flycutting the plate using the router
head is how well or how poorlyu your router head moves in a flat plane.
You'll have to get the guide frames for it absolutely perfect before you
begin your machining.

I would recommend this...but it won't be cheap...build the frame of welded
steel and be sure to add several cross member supports. Take the weldment
out and have it stress relieved. Then have the top surface of the stress
relieved weldment surface ground. NOW you will have a truly flat surface
for mounting the aluminum plate.

Hope this helps.

Smoke

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