slot, and line up the extrusion nuts with the holes on the rail. Position the rails and start threading screws through the holes and into the extrusion nuts. If you only thread the screws lightly you can reposition the rail while moving along to line up any nuts that were a little off. Once the screws are all in place, begin tightening starting from the edge, making sure the keep the rail as square as possible with the extrusion.


Attach all rails to their extrusions this way; the two y-axis rails as well as the much thicker gantry.

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The base is comprised of two 2040 aluminum extrusions, 4 base plates, and the "Base" packet of hardware.


Insert the screws into the plates as shown, threading an extrusion nut onto the screws. Leave the extrusion nuts loose on the screws. Note that two of the four plates will be flipped.Slide the base plates onto the ends of each extrusion. The large hole on the base plates should be on the outside of the machine. Hand-tighten each screw for now. Slight adjustments may be needed later in assembly, so don't tighten the screws down completely just yet.


To put the rails together use the big bags of rail screws and extrusion nuts (T-nuts). There are a few ways you can do this, but we find this method to go fairly quickly. Start by feeding enough extrusion nuts into the top and bottom slots on the tall face of the extrusion for each hole on the rail (Should be 20 holes on the 1m rails and 30 holes on the 1.5m rails). To be more efficient, do this for both rails on each side at the same time. Now place a rail above/below the extrusion nut 

Safety

For information regarding your electronics control box please refer to this online PDF.

The Spindle Carriage and Spindle Mount

The Motor Plates

The Base and Rails

Using the pack of self-tap screws and accompanying Torx wrench, attach a Y-Axis rail to both base plates on a base extrusion. Be careful on first assembly to tap the screws in straight. It is possible for screws to tap in at an angle. Slide the first belt clip onto the outside of the rail. Feed the belt through the Y-Axis assembly (with motor plate on the outside), and align the wheels with the rail to slide the assembly on. Be careful not to twist the belt during this step! Slide on the second belt clip. Do this again on the opposing rail.


Attach the other end of the rails to the opposing base plates.


Carefully lift the gantry and place one end on the inner Y-Axis plate of one side. Gently allow the other side to rest on the rails. Using 2 self-tap screws, lift the gantry and line up the screws with the extrusion holes. Do NOT let go of the gantry until at least one screw is fully in! Keep the gantry held up with one hand, and screw in the top two self-tap screws with your other hand. Four screws will suffice to hold this side of the gantry for the time being. Slide on the first belt clip, and feed the belt through the main assembly. Lift the gantry very carefully, align the wheels on the rails and slide the main assembly onto the X-Axis. Make sure the belt doesn't twist during this step! The gantry and main assembly are heavy; having something to prop up the gantry while the main assembly is slid on would be very helpful. Now, slide on the second belt clip. Slide the main assembly further down the rail to make lifting the gantry easier. Lift the gantry and slide the opposing Y-Axis Assembly into place. At this point, the gantry might not meet up with the second plate. The gantry should be very close to being flush with the Y-Axis plate. If there is a gap, or if the gantry reaches too far, adjust the position of the Y-Axis with a rubber mallet (or similar) until the gantry meets up well with the plate. Attach the gantry with self-tap screws. Fill the mounting holes with self-tap screws on both sides of the gantry.


Go back to all of the wheels with eccentric nuts now and "point" them toward the rail. This should cause the wheels to engage with the rail. Be cautious not to over-engage the wheels with the rail as this will require much more effort from your motors to move the machine! You will feel a bit of resistance when the wheels engage with the rail. If you can't easily spin the wheels with your finger, they should be well enough engaged. Once engaged, tighten the wheel into place with the allen key. Engage all of the eccentric wheels on each assembly.

We will now assemble the motor plates using the hardware from the "Motor Plates" packet.


Begin by attaching the bearing pulleys to each plate. Make sure to tighten the nuts on firmly because a loose pulley can lead to mechanical problems! The gear pulleys are to be attached to the motor shaft.


Now attach the angle brackets to the assembly with the screw heads on the inside (otherwise the screw and nut would interfere with the belt). Make sure to use the proper side of the bracket! Attach the motor plate to the bracket to complete assembly. Do this for the X-Axis and Y-Axis assemblies.

What Next?

For connecting your spindle to the VFD please refer to this online PDF.

Your Routakit HD is now fully assembled! If you haven't yet, stop by our forums for assistance, inspiration, or to just chat with other CNC enthusiasts!

Assembling your Routakit is fairly straight-forward. Keep in mind these instructions reflect the method that we find to be the easiest to follow, and is by no means the most efficient for everyone. You may find some parts easier to do another way, which is great! The machine depicted in these instruction is an earlier model, hardware and parts shown may vary slightly to your kit.

To assemble a wheel, place a bearing in one side of the wheel. Insert the wheel screw through the bearing. Thread a washer onto the screw and into the wheel. Thread the second bearing onto the screw and press into wheel. Thread the second washer onto the screw. The wheel is now ready to be installed on a plate!


NOTE: When installing wheels with eccentric nuts, take note of the nut's orientation. One side of the nut has a round face. This round side should sink into the hole that the wheel is being installed in. For easier assembly, thread the nut onto the screw until hand-tight and the round part of the nut has sunk into the hole, then position the nut such that it "points" away from rails that the wheel will be engaging.

Belt Clips

More information about setting up the machine coming later, in the mean time please check out our forums for more information or please reach out to us with your questions.

Assembling Wheels

Putting It All Together

The ball screw is composed of 4 parts; the screw with assembled housing (1), the top bearing and housing (2), the bottom bearing and housing (3), and the ball nut (4). The bearing housings come with their respective hardware for securing to the ball screw. Locate six (6) M5 screws in the packet labeled "Ball Screw".


First slide the ball nut onto the ball screw housing and secure it in place with the six M5 screws.

Next install the top and bottom bearings. Secure the bottom bearing with the provided clamp. It can be difficult to put on so you will want some pliers or other tool to assist. Secure the top bearing with the provided nut, ensuring to loosen the set screw beforehand, and tighten the set screw when in position.

NOTE: Do not torque the top bearing nut to the point that the bearings have difficulty turning!

When operating your Routakit please take the necessary safety precautions.


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Using everything in the "Belt Clips" packet, assemble the belt clips as shown. Three belt clips will have a bracket attached. The clips with a bracket will use the thinner spacers, and those without brackets use the thicker spacers.


Open the bag of belts and roll them out. There will be 2 shorter belts and 1 longer belt. The 2 shorter belts will run along the Y-Axis and the longer belt will run along the X-Axis. Loop the belt through the clips as shown. You may need to adjust belt length later on, so give a decent amount to grab onto after installation. When

Electronics

The Ball Screw

Motor Installation And Belt Tightening

The Y-Axis Assembly consists of an larger outer plate and a smaller inner plate. It will use hardware found in the "Wheel Kit" and "Y-Axis" packets.


First attach wheels to the plates as shown, aligning the eccentric nuts to "point" downward for ease of assembly. Remember that the resulting assemblies will be a mirror image of the other. Using the Y-Axis hardware, thread the screws through the plates and re-thread the spacers. Attach the inner plates now with a lock washer and nut on each screw.

The Z-Axis motor will be attached using the Z-Axis Motor Mount Plate and the Z-Axis hardware packet. Assemble the plate as shown using the provided hardware. Remove the 4 screws from the top bearing housing as shown, this is where the plate will attach. Attach the coupler to the ball screw and tighten the bottom set screw. Slide the assembled Z-Axis Motor Mount Plate around the coupler and attach with the 4 M4 screws provided.


Install the belt motors by lowering the motor pulley into the belt loop, while making sure that the back pulleys sit around the belt. Using hardware found in the "Motor Plates" packet, mount the motor.


NOTE: SD Model shown in images. Same concept.


Pull the belt clip without the bracket all the way to the base plate and secure it in place. Pull the belt clip with the bracket toward the other end.


Feed the tightening screw threads through the holes on the base plate. The belt should be fairly snug before the clip fully reaches the base plate. If it is not, feed more of the belt through the clip until it can only reach ~0.5 inch from the base plate without added pressure. Make sure the belt properly engages the motor pulley and the belt does not hang off the top or bottom of the back pulleys! Now thread the wing nut onto the screw and tighten the belt. The belt should be tight enough that a gentle tug will not pull it more than an inch from the extrusion. The tightness of the belt is important, as a belt that is too loose may experience skips on the motor pulley during operation while a belt that is too tight may lead to misalignment!

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The Y-Axis Assembly

The Spindle Carriage consists of the carriage plate and 6 steel wheels from the Wheel Kit.


Install the 6 steel wheels as shown, and aim the eccentric nuts inward. If you have a Spindle Mount plate like the one shown here, you will need to thread the 4 corner holes with 20mm M6 screws, provided in the Z-Axis hardware packet, prior to installing the carriage.


The Spindle Carriage is attached to the ball nut by way of 4 screws from the Z-Axis hardware packet. Slide the carriage along the rails from the bottom up. Align the carriage with the ball nut and attach using the 4 screws. Once attached, engage the wheels with the rails. To maintain a centered carriage, alternate engaging wheels between rails. Once all wheels are properly engaged, tighten the wheels in place using an allen key. There are access holes in the X-Axis plate to reach the wheels.


If you are installing a Spindle Mount plate, attach the plate to the spindle with the provided hardware, and slide the plate onto the carriage screws. Secure the spindle mount plate to the carriage with the provided lock washers and nuts.

The X-Axis (Main) Assembly

Click Images to Enlarge

Assembling a Routakit HD

The Main Assembly consists of two plates, one with a rounded rectangular hole in it (plate A) and one with additional holes at the top and bottom (plate B), two steel rails, wheels, and the ball screw. We will be using hardware found in the "Wheel Kit", "X-Axis" and "Ball Screw" packets.


Begin by attaching wheels to the plates in the slots shown. Ensure the wheels on plate B are on the same side as the counter-bore holes (holes that are sunk into the plate). Note, the plates shown are already assembled, but it is much easier to install the wheels as the first step in assembly. Position the eccentric nuts to point downward, since the rail will be above them. When installing the wheels be sure to put one washer between the bearings of the wheels and another washer between the bearing and plate.


Start the Main Assembly by threading the six (6) large screws through the holes in plate A as shown. Lay the plate on the table with the heads of the screws down, and thread the spacers back onto the screws. Taking note that the counter-bore holes in plate B must face inward, thread the screws through plate B's matching holes. Carefully lift the assembly onto one side. Screw the main assembly to the rail extrusions, making sure the rails are facing inward.


Using the hardware from the Ball Screw packet, attach the ball screw to the main assembly.