DIY plasma/router table

**acourtjester** · 12-18-2011, 11:20 AM

Hi
This is for those whom are interested in building a plasma/router table. This is a true DIY project as many of the parts are shop made. The aluminum parts are cast using the “lost foam” method and how they are machined in place of vender supplied parts. I am retired (more time then money) and have all the tools needed and will share my methods with you. So far I have used a waste oil furnace to melt the aluminum and a lathe and mill to machine the parts. If you want more detail you may email me with your questions. A hot wire cutter was used to form the foam and was coated with wall texture type plaster.
Jigs were made to assist machining on both the lathe and mill and are pictures here.

Have fun

Tom

**acourtjester** · 12-18-2011, 11:29 AM

I am using 1” shafts for “X” and ¾” shafts for “Y”. These are the end and center supports that I cast and machined. The clamping bolt are 5/16" fine threaded allen head. When I finish casting a machining the remaining lineear bearing carriers I will start on the base for the table. And order the stepper motor and electronics needed.

**acourtjester** · 12-18-2011, 11:50 AM

Other info
The jigs for the mill were 3/16" X 2" X 3" angle the I chucked in the lathe are trued up to 2 outside surfaces. This will made the angle had a true 90 degree and will clamp the part being milled at a true 90 degrees to the table surface.
I could only find 1-1/2" foam so I needed to hot glue layers to make enough for the size parts I wanted. Here is the 1" linear bearing slider cut from 4 layers of foam or 6" long. The wall texture stuff can be bought from lowe's or Home Depot just mix with water. When mixed it can be stored for a long time in a closed container.

**Gadget** · 12-18-2011, 01:29 PM

Very nice write up Tom. I need to get started on the hot wire foam cutter so I can re-engineer my table.

**INSANITY** · 12-20-2011, 02:53 AM

Awesome work Tom. I'm still trying to finish my manual hot wire table. It's so close to being done yet it has gone untouched for over a year. Too many irons in the fire I guess.

-Aaron

**acourtjester** · 12-25-2011, 10:08 AM

Adding to the parts needed I cast and machined a holder for my plasma torch (P-80).

**Gadget** · 12-31-2011, 08:25 PM

Great work Tom. Your boring tool setup gave me an idea on how to use mine.

**brucer** · 01-01-2012, 02:03 PM

i'm liking the torch holder tom, good job.

**acourtjester** · 01-01-2012, 02:29 PM

Ran in to a string of bad castings for the larger linear bearing slider changed the outer covering material. I was using wall texture mix which took over a day to cure, switched to dry wall joint cement. Bad idea it set up fast but must have kept some moisture as the pours of the aluminum were very violent. None of the casting was usable and went back into the melting pile.

Later
Tom