Due to variations and differences in quality of the aluminum extrusion, WCP will install all tube plugs into the ends of the tubing where they are required. We do this to ensure all tube plugs fit correctly. Step 1 can be skipped as it will be completed before shipping.
When installing the 2” x 2” tube plugs, the following illustrations show the maximum amount of bolts that can be added to each tube. We have provided the amount that is necessary for the cart to be assembled correctly and more may be added if desired. Each tube plug only requires two bolts per side as opposed to the three seen in Step 1. Additionally, only four bolts are needed to attach one tube to an adjacent tube.
Slide a 2” x 2” tube plug into the tube. Align the tapped holes on the sides of the tube plug with the clearance holes in the tubing. Install the six #10-32 x 3/8”L BHCS.
Repeat this step on all 2” x 2” tubing that has the same hole pattern on the ends. There will be 33 plugs in total that need to be installed.
Some plugs may not be a slip fit and may need to be tapped in with a mallet. This is due to the inconsistency with the tubing.
Slide a 1” x 1” tube plug into the tube plug adapter. Then slide both into the tubing. Align the tapped holes on the sides of the tube plug with the clearance holes in the tubing. Install the two #10-32 x 3/8”L BHCS.
Repeat this step on all 1” x 1” x1/16” tubing that has the same hole pattern on the ends. There will be five plugs and adapters in total that need to be installed
Some plugs may not be a slip fit and may need to be tapped in with a mallet. This is due to the inconsistency with the tubing.
Slide a 1” x 1” tube plug into the tube. Align the tapped holes on the sides of the tube plug with the clearance holes in the tubing. Install the two #10-32 x 3/8”L BHCS.
Repeat this step on all 1” x 1” x1/8” tubing that has the same hole pattern on the ends. There will be ten plugs in total that need to be installed.
Some plugs may not be a slip fit and may need to be tapped in with a mallet. This is due to the inconsistency with the tubing.
Place tubing on a flat surface as shown below. All #10-32 rivnuts should be facing up with the 1/4-20 rivnuts in each corner facing down.
Install the four #10-32 x 3/8”L BHCS screws into each tubing plug in the locations shown below.
Assembly for this step will be easier if all components are placed on a table so that there is access to the side holes.
Place the MDF Cart Base on top of the aluminum structure from the previous step. The counter bores in the MDF Cart Base will line up with the rivnuts in the tubing. Install all #10-32 x 1.25”L bolts.
DO NOT over tighten the bolts.
Install all tubes as shown in the locations shown below. Use four #10-32 x 3/8”L bolts to secure each one in place
Place tubing on a flat surface as shown below. All #10-32 rivnuts should be facing up.
Install the four #10-32 x 3/8”L BHCS screws into each tubing plug in the locations shown below.
Assembly for this step will be easier if all components are placed on a table so that there is access to the side holes.
Install the assembly from the previous step onto the assembly from step 8. Use four #10-32 x 3/8”L BHCS in each tube plug in the shown locations.
Flip the assembly from the previous step upside down, as shown in the image below. Attach each caster using three 1/4"-20 x 3/4” L BHCS.
Flip the assembly right side up, as seen below. Align the Aluminum Cart Top with the rivnuts in the top of the cart assembly. The counter bores in the aluminum sheet will be facing the rivnuts. Use twelve #10-32 x 1/2”L BHCS to attach the sheet to the cart.
If an enclosure is not to be installed, additional #10-32 x 1/2”L BHCS can be added into the unused holes.
Install the four 3D printed Corner Guards using three #10-32 x 3/4”L bolts each. There are two different versions of this part that look very similar. The limit switch version (WCP-0342-018) will have a clearance notch for the Y axis limit switch. This part will go in the back left corner, as seen in the image below.
After moving the Router Stand to desired location, the Router Stand can be locked into place to prevent movement and can be leveled as well. The leveling process does not require precision and is mainly to prevent the Router Stand from rocking as the machine is operated.
To prevent movement, rotate the red knob located inside the caster. This knob will lower or raise pad in the caster. Lower the pad till the wheel is lifted off the ground. Repeat this step will the remaining casters. Ensure that each pad is touching the ground.
The following sections cover the assembly instructions for the OMIO CNC Router Stand (Mobile Cart)
Blue Loctite (McMaster P/N 1004A12) is recommended on all bolts that thread into a tapped hole.
Install all tubes as shown in the locations shown below. Use four #10-32 x 3/8”L bolts to secure each end of tube in place. Rivnuts need to be facing up on each tube.
Install all tubes as shown in the locations shown below. Use four #10-32 x 3/8”L bolts to secure each end of tube in place. Rivnuts need to be facing up on each tube.
Place the MDF Short Shelf and MDF Long Shelf on top of the aluminum structure from the previous step. The counter bores in the MDF Shelf will line up with the rivnuts in the tubing. Install all #10-32 x 1.25”L bolts.
DO NOT over tighten the bolts.
Install all tubes as shown in the locations shown below. Use four #10-32 x 3/8”L bolts to secure each end of tube in place. Install as many sets of dividers as desired.
Some angle iron may be installed on the wood base directly under each 1” x 1” piece of tubing to help prevent sheets from sliding around, if the cart will be moved often. This is an optional addition and parts are not included.
