Step 1:
Remember, this unit was designed for the basic Shark. You will need to change dimensions as needed.
When machining parts, I used double sided carpet tape to hold the material to a scrap board. You can use other methods. Also, before trying to build or use this, remember to use your own judgment first. If something or some step looks stupid don't do it. If you are confused about any step, ask me, or someone who is experienced. Think things through and take responsibility for your actions. Have I left anything out of this disclaimer?
Step 2:
All holes are marked by the Shark then drilled through on the drill press. I did this for accuracy. You can use any method you trust.
I used plastic that I had on hand, so I planned cuts based on sizes of my material. Use whatever material you think is appropriate.
Be sure to double check tools, toolpaths, material thickness, feeds, and speeds, etc.
Cut the board that holds the rack, to a width that fits your Shark. Build and mount support arms to the gantry first, then measure to see what width is needed.
Step 3:
Check to see if the center of your router chuck extends 1.25" past the front of the gantry sides. If not, modify your design so that the center of the pinion gears is in alignment with the center of the chuck.
When mounting the pinion gear to the side supports, use the lower hole in the support arm. I used two holes so that the supports can be used on either side of the gantry. The axle is locked by using a thumb screw. Drill and tap holes for this purpose.
Step 4: I would also really like to see results of your work, both the device, and projects. Please post stuff.
Get ready:
The Mounting Arms:
- Mounting arms
I'll post the rest in two more posts.
Bob