Build Instructions v13.04

You have read the System Overview, Getting Started guide, familiarized yourself with the BOM, ordered, and received all the parts? Great! Time to assemble a Lasersaur.

Resources

• CAD model (exclusive to beta supporters)
• BOM (by subsystem view)
• this manual
• the mailing list

Tools

• metric hex keys (preferably ball-point)
• screw drivers: medium sized Phillips, tiny flat head
• pliers and side cutter
• utility knife, the snap-off kind
• metric caliper and ruler
• soldering iron
• hot glue gun
• heat gun
• power drill and drill bits: M3, M5, M6, M16 (or 5/8")
• countersinking bit (90deg)
• hacksaw
• digital multimeter (measuring current, connectivity)
• Dremel (optionally)
• ...

General Tips

• Follow the CAD model. It's most up-to-date (images are often outdated).
• In the CAD model use the Distance/Measurement tool to get all the positional specs you need.
• Use the BOM's by-subsystem view to get details on the parts.
• Think ahead when planing the next steps and familiarize yourself with all the parts (esp. screw sizes).
• Try to keep frame tolerances under 0.5mm (0.02") and build on a flat surface.
• T-slot nuts (post-assembly) may turn in the slot during assembly. By loosening and re-tightening this can be prevented. It takes a couple of minutes to get the hang of this. which makes the connection a bit more prone to vibration
• Tighten frame screws well but not brutally tight (tslot nuts can break at excessive torque).
• Any screws attaching acrylic parts must be lightly tightened. Otherwise the acrylic will crack (either right away or after some time).
• When you run into problems consult the mailing list. A good description of what you need help with (possibly also some images) will go a long way for getting good answers.

Assembly Steps

1. frame-gantry

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2. frame-table

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3. frame-outer

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4. frame-door

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5. y-cart

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6. y-drive

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7. x-cart

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8. x-drive

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9. electronics

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10. optics-laser

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11. frame panels

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