evolver56k published a new build:

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Started out with 11 uncut pieces of V-slot

DSC_9472 by evolver56k posted Mar 28, 2017 at 9:22 PM

Set up the miter saw with a blade capable of cutting nonferrous metals. I also added a 1500mm section of 40x40 as a fence:

DSC_9473 by evolver56k posted Mar 28, 2017 at 9:22 PM

It's bolted through on both sides of the blade from the fence mounting holes built into the factory fence. Then I cut the fence in two, not moving either side afterwards and added an adhesive steel tape measure with the zero line on the left side of the saw kerf:

DSC_9475 by evolver56k posted Mar 28, 2017 at 9:22 PM

This allows me to then use the entire length of 40x40 to accurately measure and place a stop block on the appropriate measurement:

DSC_9476 by evolver56k posted Mar 28, 2017 at 9:22 PM

DSC_9478 by evolver56k posted Mar 28, 2017 at 9:22 PM

So, I can make the repeated length cuts on all the pieces without having to measure or accidentally cut the wrong side of measure line.

DSC_9485 by evolver56k posted Mar 28, 2017 at 9:22 PM

Clamping the piece to be cut to avoid any movement while the blade is running (and safety goggles this thing throws tiny bits of aluminum all over).

After all cuts are made, 19 pieces for the frame assembly:

DSC_9486 by evolver56k posted Mar 28, 2017 at 9:22 PM

 

This seems really solid using the 4040s as the uprights, I've gotten pretty far with the cube today after work. I've severely underestimated the quantities of screws and nuts though. I ended up using hex bolts with lock washers to hold the inner corner brackets on all the beams, and the black screws for the plates.

Squaring up all the beams was a major pain and took the most time. I started on one top corner and worked my way around, then flipped the cube over and did the same for the bottom beams.

DSC_9487 by evolver56k posted Mar 28, 2017 at 9:22 PM

DSC_9490 by evolver56k posted Mar 28, 2017 at 9:23 PM

DSC_9492 by evolver56k posted Mar 31, 2017 at 8:04 PM

DSC_9493 by evolver56k posted Mar 31, 2017 at 8:04 PM

DSC_9495 by evolver56k posted Mar 31, 2017 at 8:04 PM

DSC_9497 by evolver56k posted Mar 31, 2017 at 8:04 PM