Great job. Thanks for sharing, I learned a lot from the detailed explanations.
Thank you. It's my goal to pass on what I can if it will be of some use to someone.
Awesome work and thanks for sharing. Really nice machine you designed and built.
Thank you. My pleasure to share.
Wow! Impressed! Nice project and well done. Thanks for the effort in this great write up.
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Thank you.
For the final pictures here is the box building process. My son and I just finished crating it up for shipping. Hopefully the warehouse guys won't destroy it during transfers, I have great confidence in the truckers, but I've watched the warehouse freight handlers on forklifts.
The pallet was custom made to fit the machine frame. Actually the machine frame was designed to bolt down on a pallet that allowed access by a forklift or a pallet jack. I designed the pallet very early in the project and built the frame accordingly. The center of gravity is pretty high, so a nice wide pallet is in order. I managed to get it on a 48x44 standard pallet.
The legs are bolted to the 4x4s with 5/8 carriage bolts. There are 2x4s for the top stringers with 7/16 wafer wood over that.
Bolted down and wrapped up, the spool rack pieces are screwed to the pallet. Other bits & pieces are bubble wrapped and boxed. Shipping the test run product with the machine, 3 spools of it.
Now we build the walls of the box. Each side took a 4x8 sheet of wafer wood. The walls are about 5 feet high. So first install the sides and then attach the 2x3 corner supports.
Then add the top supports and make a pass with a router to trim to length. The white speckles are sawdust on the camera lense.
A view from the bottom
And ready to ship, about 750 or so lbs. worth. There is about $100 in materials in the crate. The router makes nice clean and square edges and beats the heck out of measuring and sawing. Stapled then screwed. The staples make quick work of holding things in place and the screws make sure everything stays in place.
After I get back from the freight terminal tomorrow, I think I might take the rest of the day off.