Modified X-Carve and Custom 4-Axis CNC Controller

Here is my fully customized X-Carve!
I originally bought it in 2015 but I didn’t do much with it during College. Fast-forward to 2017, I found myself wanting a machine capable of handling demanding production run, better 3D carving, and to do it all on an Open Source platform as to make future expansions possible.

I quickly ditched the TinyG GRBL shield w/Arduino Uno and pick up some control cards from Mesa, specifically the 7i76/5i25 card combo.

With Mesa boards, you need to use LinuxCNC, so I download a 32-bit kernel of Linux (Wheezy 2.7.14) to a spare computer and got started.

The design files can be found by going to my GrabCad + Thingiverse pages –

The bill of materials is listed below –

1 7I76-5I25 PLUG-N-GO KIT
1 DROK LM2596 Analog Control Step-down Regulator Module
1 DC Fan (120mm x 120mm x 25mm 24V)
1 Mesh Dust Filter for 120mm Fan
3 DIN Rail
1 IEC320 Inlet Power Socket
4 KL-5056 Stepper Motor Driver – 32 bit DSP Based
1 Emergency Stop Button Switch
25ft 4 Pin Cable
1 Antek Linear Power Supply – 500W 30V 16A Peak 25A
3 Wall Outlets from Home Depot Find ones you like / feel are safe enough using
16ft Led Strip Lights
1 Misc. Hardware Nuts, Bolts, Standoffs, Crimp Connectors, Spare Fuses, 2 Extra Limit Switches
2 Ogrmar SSR-25 DA Solid State Relay with Heat Sink
1 18 AWG Gauge Stranded Hook-Up Wire Kit
~30pc Heat Shrink Tubing
1 Shop-Vac
7 Uxcel 16mm Thread 4-Pin Panel Mount Wire Connector
2 8 Circuit 20A Terminal Block

Makerbot 3D printer

I am completely flabbergasted. For Christmas this year, my father got me a Makerbot. To be specific, it’s a Make Replicator 2 Desktop 3D Printer.

It can do so much I feel nearly overwhelmed to be honest. I’ve made so many things already, I’m all over the place. Just to show its capabilities, here’s a printed Yoda bust-

1951 Van Norman Milling Machine

I was browsing Craigslist one day when I found a 1951 Van Norman milling machine for [I’ll edit the price back in once I sell this ;)]. This was a 2000 pound monstrosity of a piece of machinery, but I had to have it.

Unfortunately for me, it was in Long Island. Luckily, my Grandpa had a Ford King Ranch Pickup Truck at the time, and he was willing to give it a stress-test!
After a 2 hour drive we were at our destination and there was a fork-lift dropping this mammoth into the truck.

We tried to drive on the highway with it, but we were terribly scared by the idea of it falling into the cab of the truck, so naturally we fled to the Ferry to Bridgeport.

From there we were in Bridgeport with a giant machine stuck in the bed of this truck. Fortunately my grandfather has a small warehouse for his old cars, and the next door tennet had a forklift! After stalling a few weeks, we had to get this thing from Bridgeport to Old Greenwich without a forklift.

We could drive the truck to my house, but we couldn’t possibly unload the machine off the truck. After some careful thinking, we agreed on renting a truck with a lift gate… We figured that we could load it onto the truck, and when we got it to my house, we could rock the machine to the gate and use movers to get it in the garage. This didn’t go so smoothly, but it did work!

What the shop in Greenwich looks like now –

Build Your Own CNC Bluechick 3.1 Kit

For my 14th birthday, I received an unassembled CNC machine kit!

This kit required me to get very creative and I learned a lot during the 5 months it took me and my dad to build it.

September 18, 2010: Mechanically done for the most part.

Nov 21, 2010: Making a router holder for my own router at school
I recommend turning your sound down before viewing the above link.

The router really is too big, I’m going to make another mount for a smaller one later on.

Nov 29, 2010: Steppers mounted and my Ubuntu rig has EMC^2 and Mach3 on it.

Additionally, my dad and I mounted the power supply and the stepper controllers to a sheet of 1/4″ Plexiglass.

Dec 3, 2010 –
I now have made a new mounting bracket made for a much smaller router. It looks fantastic if I do say so myself.

Feb 2, 2012 –
Here’s a video of the CNC making a puck for my Unhappy Skate longboard slide gloves!
[Removed until I find this video again… (2/18/18)]