X-Carve: Example Machine Setup

This tutorial is Step 2 of the X-Carve Router practice example. This portion of the example will explain parts of the X-Carve table at Spark, and how to mount the material to the machine table, install the cutting tool, and set the router speed. If you haven't yet, go complete Step 1 first.

Approaching the X-Carve

The X-Carve machine is near the main entry door into the Spark Woodshop. As you approach the machine, you'll see the following parts:

	The X-Carve table, with a 1cm X 1cm grid and threaded holes for clamping. The X-Carve controller, with a big red button on it called the emergency stop, or E-stop. A cart under the machine, which has important accessories required to use the machine (explained further below) The X-Carve spindle is a DeWalt router. It is controlled manually, meaning the user has to turn the spindle on and off before carving. The X-Carve is controlled by the attached computer.
	The important part of the controller is the emergence stop, usually shorthanded to E-stop. It is the large red button on the controller, and is actuated by pressing straight down on it. This will immediately stop the motion of the machine, but will not stop the router spindle. The router spindle is controlled manually, and must be shut off separately. Don't be afraid to use the E-stop if the machine is doing anything unexpected. To reset the E-stop after correcting the problem, twist the red portion of the button clockwise. It will spring up and the X-Carve will be ready to run again.
	Pulling out the cart under the machine gives access to the tool tray. The tools should be returned to the tray whenever they are not in use. The image at left shows the various types of tools, divided by color: RED: The two red boxes show the parts used for clamping material to the table bed. The upper box surrounds the clamping screws. The lower box surrounds the plastic clamp arms and the aluminum clamp bases. BLUE: The two blue boxes show shop cutting bits. Some may be in the plastic protective sleeve, which fits in the square pockets on the left. Others may be out of the sleeve, and stored in the holes in the middle of the image. YELLOW: The two objects in the yellow box are the collet assemblies. Each assembly contains a collet and a collet nut. One set is for 1/8-inch shank cutters, and the other is for 1/4-inch shank cutters. PURPLE: There are two wrenches, for use with the collet assemblies, circled in purple. The wrench with the red handle is for the 1/8-inch collet assembly; the larger end of the silver wrench is for the 1/4-inch collet assembly. GREEN: The green box identifies the Z-probe, which is used to set the tool length. There are also usually brushes in the tray, as shown in the image at left. Please ensure the tray is completely under the table when cutting, to prevent sawdust accumulation.

Mount Material to Table

The first step in setting up the X-Carve is to mount the material on the machine table. This requires use of the clamping parts found in the top tray of the cart.

It is also important to ensure that a spoil board is used whenever cuts are made through the workpiece. A spoil board is a sacrificial panel which protects the bed to the machine from being cut into. Several instances of careless cutting are visible on the Spark X-Carve bed. Please help prevent any more damage!

Step 1:		As shown to the left, the workpiece is red with a white core. Two pieces of brown tempered hardboard (also commonly called by the trade name Masonite) are being used as spoil boards. At least two, ideally three or four, clamps should be used. One clamp is composed of three parts: A plastic clamp arm. These are available in several lengths in the cart tray. One end is tapered, and the other end has a step pattern to engage the clamp base. An aluminum clamp base. The profile of this part looks like a toothy triangle. The teeth lock into the stepped end of the clamp arm. A clamp screw. Again, these are available in several lengths in the cart tray, with each length having color matching heads. The screws should be long enough to engage the threads in the X-Carve bed, but short enough that they can be tightened against the clamp arm without bottoming out in the X-carve bed.
Step 2:		CLAMP ASSEMBLY GOES HERE
Step 2A:		GOOD/BAD Examples go here
Step 3:		INSTALL OTHER CLAMPS
Step 3A:		AVOID CRASHING CLAMPS