CNC Router, K2CNC, KT-2525, KG-3925, Gecko, Stepper, CNC, Porter Cable Router

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CNC Machining
RC Helis & Planes

-My CNC Router!-

After many days and hours in front of the computer looking for parts and making many designs, I figured it just wasn't going to be possible to make the CNC router I wanted. It was determined by price, parts availability, time and actual construction. I opted for the K2 CNC router frame

Power Setup for Steppers

KT- 2525

KG-3925

New Servo Setup and Power Setup

First Parts

KG-3925

Stepper Motor and Power Setup for NEMA 23 stepper

Gecko 201 Drives
I finally bought some Gecko drives and I am really excited to try them out! Check them out here Gecko Drives
3-3-05

Where is that
COMMON WIRE ?

The "common" on my parallel port does not have the +5 needed. You can get this from pin 1 on the game port or one of the wires in the serial mouse.

FIRST TEST OF GECKOS
Here is the early tests of the Gecko drives, Mach 2, transformers and capacitor. Everything ran great and there was no smoke :)
3-17-05

I wired the 2 transformers in series using 24 volts from one and 12 from the other. After the bridge and capacitor you can see the voltage is at 52V. My motors are 2.1 volt each so that is Just shy of the max 25 times motor voltage!

PARTS FROM:

MPJA Supply
12-0-12 10Amp transformer
400V 35Amp bridge
3.5" 120V fan

20,000uF 75V capacitor
I either got or ordered the wrong cap. Get min 22K
Dynamic Surplus

Gecko Drive Assessment? AWESOME!! The Gecko drives are compact, run the motors beautifully and the customer service is outstanding!

First a little bit about my KT- 2525 (4-10-05) UPDATE: This version is not made anymore. (First machine ordered)
I got my KT 2525 after 5 weeks and all I can say is total disappointment. Nothing on this machine is right as well as the parts and packing of the base. K2, has been helpful in making this right and getting a new machine out to me. I am going to get the KG-3925 at a discount rate...hopefully in about 2 weeks, hopefully with no probs.

First mistake noted. No lower mount! No biggie, just get one.

Wrong side mounts!
O man. I can't even put the machine together now

Dented side. Poor packing and poor shipping (fedex)

Horrible! This bearing does not even touch. This is just one part of the X axis.

Leadscrews are bent almost 2 mm in the center! Come on.

RETURNED
KT-2525 Returned due to poor workmanship.
4-10-05

NOTE: K2 has discontinued the bearing setup secondary to so many problems. They have gone to linear bearings on this machine. GREAT MOVE K2!!

My K2 KG-3925

- Nice size, 2x4 foot piece of wood fits perfectly
- Linear bearings seem to be of VERY good quality
- Looks nice, aluminum, general machining finish
- Router mount fits very well
- Leadscrew with acetal nut is excellent
- Upgraded Z axis is very nice
- Ron at K2 seems to be making great changes
- Love the Gantry style movement
- Multi-purpose machine
- Very good customer service (thanks Ron)

DISLIKES (Updated: 06/20/2007)

- No documentation is included. (UPDATE: Document is now included)
- Nook ballscrews don't come with wipers and are loud/gritty. (UPDATE: Nook ballscrews are not used
anymore)
- Ballnut mounts are not machined well (UPDATE: New design shows no issues.)
- Poor shipping and packing of base (UPDATE: Now shipped in an all wooden boxes! Awesome!)

K2 has made some major improvements to their machines! Good Job K2!

Suggestions on ordering (design has changed so please not this if for when I ordered mine 4-27-05)
- I would highly suggest getting 2 more cross braces for the machine.
It makes the base stiffer and gives you more clamping room for pieces.
- Check into upgraded ballscrews
- The servos K2 have are very nice.
- Get the upgraded Z axis...don't mess around with the regular one.
- Get the aluminum tabletop if you can.

My New K2 KG-3925 Setup !

Here is the basic fame being put together. Everything is fitting well. 4-27-05	Here is part of the Y-axis. Pins are used to line up parts.	Nook ballscrew are used on the X and Y. They run well but have more backlash then I expected.	Size comparison to the Sherline. It almost dwarfs it!	Mounts for the Y-axis. It is on a piece of wood and on my router table.
Getting closer. Man where am I gonna put this thing? I ordered 2 extra cross braces.	The router fits well. I have to dial in the machine.	Size comparison to the T-Rex. It's tiny. I could cut custom cabinets on this puppy.	All of the wiring mess. I will have to figure out what I am going to do here.	Piece of very nice plywood with MDF. This piece is 24x24 inches and fits well.
IT'S ALIVE !! Here is my first cut with the router. As expected the endmill makes quick work of the pine. 4-29-05	Here is the setup so far. The router looks great!	Belt drive X-axis. Works well.	Here you can see the makes of the X and Z axis.	Another pic of the pulley and mechanics of the X axis
Overview picture.	CLEANING THE BALLNUT Here is what a ballsnut looks like. Pretty simple really. Just make sure the balls don't get stuck while putting it back together.	I was cleaning the ballscrew (my first experience) and lost one of the balls after it got stuck! After some head scratching I found a bearing with the same size ball and used it 3.15mm.	The beginnings of my setup. I have used a tool bench as the machines base and put the Gecko drives on the back in the middle of the X travel. 4-30-05	POWER SUPPLY Here is the power supply. Pretty simple and crude but does the job. No need for fancy stuff here. This thing is going to make a mess! Need the Schematic? Click Here
Here is the first CNC code I ran on the machine. Pretty cool!	Done, a little over 7 min. A little clean up and it will shine :)	Movie! Quicktime and 7.65 megs 4-30-05	POOR MACHINING This mount for the ballnut is not even cut 90 degrees. Such an important part	Here you can see how it is also too big causing needless stress on the ballscrew and nut.
SHERLINE to the rescue! I flycut the block and it now sits and fits much better.	For the enclosure I used this excluded aluminum. Overall it has come out nice.	POOR MACHINING The mount needs a shim for my ballnut to run free. Without it it was gritty and difficult to move by hand.	NEW X-Axis Mount This one fits perfectly. No more shim needed. 5-15-05	Here are the parts it replaced. They also sent a X one too. Will have to replace that soon.
Movie (Quicktime 13 megs) Thanks to Gerry at CNCZone, I tried a different setup and it rocks! I have less resolution but the speed is incredible and the motors have not stalled. They sound much nicer!	NEW SETUP: Flip the big and small pulley and reset your speed and steps per unit. AWESOME!!! For mm use 196.85039 steps/mm	SOLID STATE RELAY BOARD Here is my "full" setup. I bought a solid state relay board from HERE. Good quality except the heat sinks are a little cheesy. Works great!	Here are my on/off switches for the power supply and power to the relay board. I am using +5 volts from the computer's supply.	POOR MACHINING AGAIN! Unbelievable! They send me a new mount and its horribly made.
POOR MACHINING AGAIN! The sides are not even matching. I measured this over 5 times and took the average. I am getting a new mount sent.	NEW Y-Axis Mount FITS GREAT! Now we are in business. I really like how K2 changed the mounts. They are much simpler and easier to deal with. Good change.	NEW STEPPER MOTORS I've moved to NEMA 34 motors! Man these puppies are huge and heavy. Check out the mounts. CLICK HERE	I have added felt pads to he front and back of my Nook ballscrews to keep dust out. So far so good!	Here is another picture.
I used a woodcraft keyhole cutter to cut this notch. I used the Porter Cable router and base to cut it by hand. No problem. Now I can slide my top and nuts though the front of the machine.	My First Part! with the K2-3925 CLICK HERE	Look below :)

KG 3925 gets Servo Setup! (11-07-2005)

-Thank you to K2 for sending me new mounts, wires and a bunch of screws at no cost!
-Awesome packing
-Great service! Awesome job K2
-Great Servos, silky smooth I love them... I love them!
-Excellent fit on the machine and mounts.

I bought new servos from K2. They look awesome and are very smooth!	Size comparison of my NEMA 23 and the NEMA 34 servo.	Here is the Z axis. Pretty much a drop in into the router.	I choose to cut down the spacer for the Y axis so the pulleys could be closer.	Here is the X axis mounted. Awesome. The servos look great. I can't wait to try it out.
Y mount needs to be re-made since my original machine was setup for NEMA 23 steppers	I got my new mount from K2 and it rocks! Awesome work. They also sent me a new shiny belt :)		Here is the Sherline 4th axis on the K2 :) Is it time to cut a true 4th axis part.	Awesome Job K2! They work GREAT!
Setup has a front cover with Plexiglas window to check the drivers and prevent little kids fingers from getting in :)