Scaled-Up 54" x 54" Shapeoko

discussion of design changes / improvements / suggestions
superklaub
Posts: 9
Joined: Sat Apr 29, 2017 2:49 am

Scaled-Up 54" x 54" Shapeoko

Post by superklaub » Wed May 31, 2017 12:45 am

My name is Kevin Laubenthal. I am an industrial engineer/designer with over 21 years of experience.

Over the years I have had several ideas for projects that I could create on a CNC router. I started seriously considering the purchase of a CNC router in early winter of 2016. Due to the price point I focused primarily on Chinese made units, the X-Carve, and the Shapeoko 3 XXL. Unfortunately, none of these routers were available in the size I really wanted: 48” x 48” or larger. So, I began to explore what it would take to scale-up a stock unit. In February of 2017, after much research, I decided to purchase a Shapeoko 3 unit and a Shapeoko 3 XXL expansion kit.

I received the Shapeoko 3 and the expansion kit just a few days after I placed the order. I promptly assembled a Shapeoko 3 XXL and sat the rest of the leftover parts aside. During the next few months I cut several signs and plywood components. Taking the time to run these projects allowed me to become familiar with the machine and the workflow to produce usable parts.

By late spring I was ready to scale-up the router. I decided to use the Shapeoko 3 XXL to make as many of the new components as possible (i.e. the legs, vacuum table, vacuum manifold, vacuum motor mount, and laptop stand). I cut the new parts from ¾”and 1 ½” MDF. I used some salvage steel tube for the new router bed and ordered most of the rest of the parts online. The last task before building the new scaled-up router was to disassemble the Shapeoko 3 XXL and splice its rails with the shorter Shapeoko 3 rails.

Assembly of the scaled-up router went well. Thanks to lots of planning and forethought there were minimal surprises.

The new scaled up unit has a 54” x 54” vacuum table with suction provided by a three stage vacuum motor that provides a maximum of 5 psi of hold down force. The cutting area is larger than the vacuum table. The cutting area is closer to 57” x 57”.

Carbide Create and Carbide Motion work great on the larger unit. No problems.

The first project off the new router was an old Mobil Oil Pegasus sign (I actually made two – a right hand and a left hand). From tip of hoof to tip of hoof each Pegasus measured 66”. You can see pictures of the Pegasus here: https://www.shapeoko.com/forum/viewtopi ... =30&t=8809. Cutting the Pegasus sign went smoothly and it looks great. Since then, I have made several more signs and plywood cutouts all with great success.

Three photos of my scaled-up Shapeoko are attached to this thread. Here's an additional thread with pictures of the vacuum manifold, vacuum motor mount, and underside of the vacuum table: https://www.shapeoko.com/forum/viewtopi ... =11&t=8821
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Last edited by superklaub on Fri Jun 02, 2017 3:22 am, edited 2 times in total.

cgallery
Posts: 26
Joined: Sat Apr 01, 2017 9:43 pm

Re: Scaled-Up 54" x 54" Shapeoko

Post by cgallery » Wed May 31, 2017 2:32 am

Very sharp setup.

I've only seen one other user that combined extrusions, he made MDF inserts. Did you do something similar to combine them and keep them straight and rigid?

superklaub
Posts: 9
Joined: Sat Apr 29, 2017 2:49 am

Re: Scaled-Up 54" x 54" Shapeoko

Post by superklaub » Wed May 31, 2017 10:26 pm

cgallery,

I used four steel nut bars at each splice. I attached a CAD image of the Shapeoko 3 extrusion with the 3/8" x 1" nut bars located inside. I also attached a picture of the outside of the splice area showing the 1/4-20 flat head screws.

Best Regards, Kevin
Attachments
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RAIL SPLICE.PNG
RAIL SPLICE.PNG (10.78 KiB) Viewed 4320 times

cgallery
Posts: 26
Joined: Sat Apr 01, 2017 9:43 pm

Re: Scaled-Up 54" x 54" Shapeoko

Post by cgallery » Wed May 31, 2017 10:36 pm

Did you machine the bars yourself or are these available in standard sizes?

Very nice work indeed.

superklaub
Posts: 9
Joined: Sat Apr 29, 2017 2:49 am

Re: Scaled-Up 54" x 54" Shapeoko

Post by superklaub » Thu Jun 01, 2017 2:30 am

The nut bars were custom made.

Thanks for the compliments.

Best Regards, Kevin

infinity06
Posts: 2
Joined: Sun Jun 11, 2017 12:46 am

Re: Scaled-Up 54" x 54" Shapeoko

Post by infinity06 » Sun Jun 11, 2017 11:22 pm

Hows is it cutting with the expansion? I am on the fence ready to buy a shapeoko but only if i can expand it.

JeromyReno
Posts: 225
Joined: Mon May 04, 2015 11:28 pm

Re: Scaled-Up 54" x 54" Shapeoko

Post by JeromyReno » Tue Jun 13, 2017 10:28 pm

damn this is bad ass!

kevinvu25
Posts: 3
Joined: Tue Jul 18, 2017 1:03 am

Re: Scaled-Up 54" x 54" Shapeoko

Post by kevinvu25 » Sun Jul 23, 2017 10:32 pm

This is awesome, getting my xxl soon, this is giving me ideas for the future! :D

compwizard7
Posts: 3
Joined: Sat Aug 15, 2015 10:45 pm

Re: Scaled-Up 54" x 54" Shapeoko

Post by compwizard7 » Fri Sep 08, 2017 1:44 pm

Okay, this really makes me want to buy an XXL upgrade kit...

bencarlson
Posts: 1
Joined: Fri Feb 09, 2018 5:13 pm

Re: Scaled-Up 54" x 54" Shapeoko

Post by bencarlson » Fri Feb 09, 2018 5:17 pm

So, how does the slight "blip" where the two bars meet affect accuracy/cut/travel/etc?

Thanks!

-Ben
--
Avialoft - Aircraft Builder's Logbook App
https://www.avialoft.com

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