Expansion packs announced

[HDVideo]

I guess my confusion of the chosen sizes stems from the Wiki statement (I think it's still there), that sizes up to 5'x10' should be possible, I assume that was based on testing of the extrusion. So 33x33 seemed an odd choice given the stated capabilities of the parts and the fact that 48x48 was by far the most requested size in the poll. Whatever, I'm sure Edward gets a kick out of all our speculation and second-guessing. lol

[chamnit]

If someone figures out a good way to join the extrusions, you could join XL rails to the existing S3 ones. That would fit your 48x24" cutting area inside.

That's an interesting idea. With the spare parts from an XXL upgrade, you'd have three ~24" rails to play with. I think you could reasonably bolt them together because the walls are 1/4" thick and can hold a good thread. Extending the two y-axis rails would be theoretically possible without sacrificing rigidity too much.

[AnonymousPerson]

I think you could reasonably bolt them together because the walls are 1/4" thick and can hold a good thread. Extending the two y-axis rails would be theoretically possible without sacrificing rigidity too much.

A quick concept version:

Extrusion join plate concept 1 screenshot 1.jpg (105.18 KiB) Viewed 1314 times

Using a two-plate solution. Plate A is bolted to one extrusion using countersunk M5 bolts. Plate B is bolted to the other extrusion, also using countersunk M5 bolts. The two plates mesh with each other, and are bolted together with M8 bolts.

Looks kind of over-engineered.

Extrusion join plate concept 1 screenshot 2.jpg (92.7 KiB) Viewed 1314 times

Extrusion join plate concept 1 screenshot 3.jpg (83.02 KiB) Viewed 1314 times

Note - the extrusion dimenstions aren't accurate, I just walked over to my S3 with a ruler.

Pretty sure the wall thickness of the extrusion was a lot thinner in the real thing. The bolt sizes are pure guess work, etc.

[AnonymousPerson]

The concept model files (STEP format, zipped with 7-Zip), in case anyone wants to muck around with them.

Extrusion join plate concept - with extrusion.7z

(177.71 KiB) Downloaded 53 times

These links should let people grab the project files, potentially in various useful formats:

• Assembly - http://a360.co/1THqiEs
• Plate A - http://a360.co/1THr30h
• Plate B - http://a360.co/1Q5wlz8
• Example extrusion - http://a360.co/1Q5wnae

For anyone with Fusion 360, the above links might "just work" for loading them directly too.

Hopefully that's useful.

[twforeman]

Wow, that seems a bit over-engineered.

Just bolt four lengths of 1/4 steel plate inside, one on each face.

[AnonymousPerson]

Just bolt four lengths of 1/4 steel plate inside, one on each face.

Gah, didn't think of that.

[twforeman]

It's okay, I also suffer from "over-engineering disease" myself.

[dvdsnyd]

What about the spot the two sections come together. Wouldn't there be concern that the discontinuity would create a dip or some other height variation at that point?


Sent from my iPhone using Tapatalk

[sgth0mas]

What about the spot the two sections come together. Wouldn't there be concern that the discontinuity would create a dip or some other height variation at that point?


Sent from my iPhone using Tapatalk

JB weld, sand paper and patience:)

[Defy]

Good welder and slow file.