LowRider2 Dewalt DPW611 CNC plate in two halves (25.4mm)

thingiverse

Credit to Ryan at https://www.v1engineering.com/ for creating great DIY CNC options, and to peterfosseus here: https://www.thingiverse.com/thing:4834949 for the idea and OpenScad code to split this 25.4mm Dewalt DWP611 router plate into two printable sized parts that can either print separately or interleaved together (without a skirt) to print both halves simultaneously on an Ender 3 or Ender 5 print bed and later bolted together. For this remix, I tightened up gap from original 0.5mm gap on the joint between the two halves to 0.25mm and changed the original four 6.3mm holes for bolting the two halves together to six staggered 4.5mm holes to be tapped for M5 screws. I also flipped one plate so it is oriented best for printing. Be aware that the innermost four innermost holes along the joint will interfere with the Dewalt router base so I screwed in and superglued four m5x8 panhead screws in the innermost four holes along the joint up from the bottom which are flush with the top and do not protrude so they won't interfere with the router base but add support to the joint. I used longer panhead M5 screws and locknuts for the outer two holes along the joint. I printed with 8 walls, 8 top layers, 8 bottom layers, 50% cubic infill using eSun PLA+. One half took 6:52 and the other 6:25 to print. I printed the halves separately using two printers. I slid a couple m4 screws into a holes on the outside edges for alignment and then tapped for m5 screws, superglued, and secured with M5 screws and nylon locking nuts on the outermost two holes while the superglue was still wet. I built up the 611 plate assembly and checked the fit using a Dewalt DPW611 I just received. The 6-32x1" screws holding the roller brackets were just barely long enough with the 6-32 lock nuts. This is because the plate is 8mm which is a little thicker than 1/4" plate specified. I made it slightly thicker for additional stiffness. There is about 1 screw thread protruding from the lock nuts. This looks fine though. Also, the four screws that came with the router to secure the Dewalt base onto the plate appear to be pan-head M4x10mm screws. Since this base is 8mm thick, the 10mm screws are a little short to be used safely so I am going to use longer M4 screws to secure the router base to the 611 plate. I went with M4x16mm panhead screws which go up from the bottom of the plate all the way into the router base threads without protruding. My router base mounting holes in the plate were pretty good but I am going to slightly elongate one hole with a drill to better align with the Aluminum router base screw holes. I am happy with how this plate assembly came out but do anticipate cutting a new 611 plate and Y plates out of a stronger material once the CNC machine is operational just in case. The plate does feel very strong and I think it is going to work fine. I did end up using lower profile panhead screws though instead of the allen head screw I show in the picture for more z axis clearance. Good Luck!