My Built Begins

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11-11-2009, 18:54
gilv_58

4 Attachment(s)

My Built Begins

After reading some posts and soliciting some advice I decided to start putting things together today. I am sure I will still need more advice with every step.

Like I posted before I had purchased a 100mw Green laser, scanners and a case. I bought a .50" aluminum plate to use as an optics bed. I ordered a mirror mount to align the laser with the galvo block.

Here are the plate and case

Not much room on the first set up.

The second set up leaves room for a possible second laser.

Looks like I meed to get a bigger case.

Comments??
http://www.photonlexicon.com/forums/...l?cbol=3534373
11-11-2009, 19:01
Laser Ben

Looks good so far! I like the idea of using the electrical enclosure!
11-11-2009, 19:37
gottaluvlasers

looks great gil! excellent start!
11-11-2009, 19:53
Hemlock Mike

1/2" of 6061-T6 ???? WOW -- that's a chunk of aluminum!!!!!!!
Heatsinking will be no problem........ Nice but HEAVY.

Mike
11-11-2009, 20:01
f22warzone

I thought the scanner amps had to sit straight up and down for heat sinking of those chips on the bottom?
Just wondering but how much did that plate cost? Looks good tho : ) Cant wait to build mine hopefully this weekend : )
11-11-2009, 22:32
pelosh

Quote:

Originally Posted by gilv_58

Looks like I meed to get a bigger case.

http://www.photonlexicon.com/forums/...l?cbol=3534373

Or smaller parts ;)
Lovely baseplate! Just as it should be.
11-12-2009, 03:35
Doc

Meaty! :)

As f22warzone said; those scanner amps would be better stood up vertical, make sure you use heatsink paste between them and your baseplate.
11-12-2009, 04:03
gilv_58

Thanks for the comments

With respect to the .50" plate:
1) I wanted a good heatsink
2) The weight (about 7 lbs or so) adds to the stability of the scanner unit. It measures 11"x13"
3) It only cost me $26 at a local place (vz $70 for ordering online or $160 for a breadbord)

With respect to the scanner amps placed standing up The case has no room for that. The voltage regulating chips (the parts that will get hot) are attached to the amps heatsink, the heatsink angles down and continues to the bottom of the amp thus I think it may not make a difference how they are placed. It may even be better if they are placed like I placed them because there is a larger surface transmitting the heat away from the amp circuit board. I'll take a pic to show what I mean.

I have school tonight so the drilling and tapping of the base plate will take place over the weekend. I hope I get the mirror mount and mirror this weekend so I can line things up.
11-12-2009, 04:08
Insanity

Looking good.

I reckon you should leave the scanner amps as they are. Standing them up saves space, but leaving them as is allows access to the trimmers for any tuning you might need to do in future. Having them vertical will make tuning a bit of a nightmare.

Just my 2p

Mark
11-12-2009, 18:29
gilv_58

4 Attachment(s)

The small case was bothering me all day long, so on my way to school I stopped my my local computer and electronics store. Picked up this case that is intended for home entertainment (PC based Digital Video Recorders) systems.

After removing some screws I have an almost perfect case. I still need to remove the dividers by popping off a few rivets.
11-12-2009, 18:39
gilv_58

The case has two fans, I'll have to turn them around because they are installed to plow hot air out of the case. I take it I want the case to have a positive air pressure to eliminate smoke and other stuff from getting in. I'll install some Heppa filters to fileter the air being pushed into the case. I am going to glue a plastic plate on the back vent grill and leave the vents opened on the opposite side of the case.

I will make a metal plate to cover the power supply vent area (last picture rear left opening). I will put the AC inlet, switch and key switch on this plate. Then I will remove the two dividers from the case. These are riveted on.
11-12-2009, 19:20
Laserman532

Your Ultramount http://www.microlaserlabs.com/produc...e28krtnu9s3di5 and complementary front surface mirror on on their way.

That is one monster piece of aluminum, be careful because your base plate will suck all the heat out of the room:D
11-12-2009, 19:30
gilv_58

Thanks Pat.

Yes I noticed could turn my A/C off when I bring in the plate!!!
11-12-2009, 23:47
CRFultz

That is a nice case, Gil. Look forward to seeing your progress. Where abouts you from? There might be enough of us from this neck of the woods to get a LEM going at some point. My projector is under construction as well, right now it's just components scattered all over the work bench. Hopefully this weekend I can start assembly.
Keep the pics coming:)

Chuck
11-13-2009, 07:29
f22warzone

Hey that would be cool as i am from Texas to ....bout 40 min north of dallas : ) and my projector is also in the building this weekend : )
11-13-2009, 07:53
gilv_58

f22 I am in San Antonio, do you work for Lockheed?
11-13-2009, 08:01
f22warzone

No i wish still in college : ) UTD
11-14-2009, 11:08
gilv_58

2 Attachment(s)

Because I bought the plate from a local metal dealer (and saved myself $30 in the process) I had to grind the edges smooth.

I ground using 60, 80, 120 and 220 grid wheels.

Now I have lots of room for one more laser.
11-14-2009, 11:34
gilv_58

I am standing up the amps put placing them at a 45 deg angle exposing the pots. This will should allow me to adjust them later if necessary.

Just waiting on the adjustable mount and mirror to do the final location. The I'll drill and tap the optics bed.

Comments?
11-14-2009, 13:37
gilv_58

laserman532

The ultramount and mirror arrived today!!!! That was very fast.Thanks a lot for the mirror.

One question (I am a real nub) what to you glue the mirror with? I take it you glue it to the front plate?
11-14-2009, 16:09
Laserman532

Quote:

Originally Posted by gilv_58

laserman532

The ultramount and mirror arrived today!!!! That was very fast.Thanks a lot for the mirror.

One question (I am a real nub) what to you glue the mirror with? I take it you glue it to the front plate?

you can use just a very small dab of epoxy on each corner.

Can you make an angle bracket or do you need me to make you one?

after sending you that mirror i came up with some others you might be more interested in... http://www.microlaserlabs.com/produc...9vftf3eg4llqq0

if you would prefer the smaller one i can send one of these to you
11-14-2009, 17:06
gilv_58

Pat
Thanks after a quick dash to the local hardware box store I got some 5 min Epoxy. Epoxy is setting with mirror on mount.

So I need an angle bracket? I take it you mean an "L" angle to mount the adjsutable mount to? I was going to mount it directly to the optics table, the .50" aluminum plate.

The bean of the laser already hits low (2mm lower than the center of the hole on the movable plate) of the mount. I take it is no big deal now, but raising the mount even more to install it on the "L" bracket?
11-14-2009, 17:34
Laserman532

Quote:

Originally Posted by gilv_58

Pat
Thanks after a quick dash to the local hardware box store I got some 5 min Epoxy. Epoxy is setting with mirror on mount.

So I need an angle bracket? I take it you mean an "L" angle to mount the adjsutable mount to? I was going to mount it directly to the optics table, the .50" aluminum plate.

The bean of the laser already hits low (2mm lower than the center of the hole on the movable plate) of the mount. I take it is no big deal now, but raising the mount even more to install it on the "L" bracket?

nope, sounds like you are good. Most peoples beams are higher. When the ultramount is mounted to a flat surface the center of the free plate is .75" above that surface (it is not critical you hit exact center it will work just fine). Sounds like your golden for now, sorry the mirror was so big, but as usual about 30 minutes after I made your shipment I found a stack of nice smaller mirrors...oh well.
11-14-2009, 18:40
Laser Zone

Dont forget to drill out your 289 + screw holes for your optical deck !! :D
11-14-2009, 18:44
Laser Zone

Oh , and anodize the optical deck too !!
11-15-2009, 15:02
gilv_58

Quote:

Originally Posted by Laser Zone

Dont forget to drill out your 289 + screw holes for your optical deck !! :D

Laser

What are these for?

I was already planing on anodizing the plate.

I am a bit confused on how to drill it. I am thinking in drilling and spot facing the bottom and get screws to match the threaded components. Screws come in trough the bottom with the screw head fitting inside the spot face.

Or place a a spacer between the optics table an just let the heads of the screws stick out the bottom of the table (but not touch the case bottom)?

Any ideas, comments?
11-15-2009, 15:18
gilv_58

2 Attachment(s)

The mirror is now glued to the adjustable mount. Thanks once again to laserman 532. The ultramount is designed and built very well (I'm an engineer) and laserman provided me with a mirror that works well for my needs.

Now to drill the optics bed for the laser, the adjustable mount, the galvo block and the two amps. The amps power supply and the laser's power supply will NOT be installed on the optics bed. I'm attaching these directly to the case.
11-15-2009, 20:03
no-esc

Quote:

Originally Posted by gilv_58

The mirror is now glued to the adjustable mount. Thanks once again to laserman 532. The ultramount is designed and built very well (I'm an engineer) and laserman provided me with a mirror that works well for my needs.

Now to drill the optics bed for the laser, the adjustable mount, the galvo block and the two amps. The amps power supply and the laser's power supply will NOT be installed on the optics bed. I'm attaching these directly to the case.

Looking Outstanding so far....

I need to get a camera so I can start posting pics of my build.
11-16-2009, 08:29
gilv_58

1 Attachment(s)

I need an "L" angle that works like this.
Does anyone know here I can get one?
11-16-2009, 08:45
Laserman532

well the fastest way is to go to home depot an buy a angle bracket and drill it yourself, slotting is more difficult depending on how long you want the slot.

The ultramount has mounts on both sides if you are good with your drill you can drill through the baseplate but that gives you no freedom of movemet.

I would go with the home depot method, I magy get a chance to make some angle brackets today, small market, hard work...
11-16-2009, 09:22
sugeek

L-Brackets

https://www.ctlasers.com/purchases/brackets-p-61.html

But the home depot method will get you rocking today, rather than next week. ;)

-Adam
11-16-2009, 11:41
gilv_58

I have another nub question. I have been planing on how to install align the laser, mirror and galvos all day. I though I may wish to make the laser beam visible while doing so. SO here is the question specially when I read about sealing the projector case, positive air pressure inside the case, and keeping stuff off the mirrors.

Is it ok to run a smoke machine with the case filly opened while trying to alling things?

Do I need to clean things after I do so?
11-16-2009, 12:00
ElektroFreak

My own personal advice to you is to cut a piece of plywood that is the same size as your aluminum plate. Align everything on this plywood and drill and bolt it down. Then remove everything from the plywood and use the wood as a drilling template for your aluminum plate. It can be tedious, but it works well.

I wouldn't worry about the smoke machine too much.. it shouldn't gunk things up too much in the time it takes you to align, not to mention the fact that even if you close the case and filter your fans, particles are still going to get in there and muck up your optics. Throughout the life of the projector you will need to clean the optics periodically, so don't let that idea worry you. Just be gentle, use good q-tips and >90% isopropyl alcohol or methanol and you'll be just fine cleaning your galvo mirrors, etc.
11-16-2009, 16:33
CRFultz

Gil I made some that will work for ya but they might be a tad to tall. I will be doing some machine work this weekend. If you give me the exact dims, I will machine a couple for ya. let me know.
http://i243.photobucket.com/albums/f...z/DSC01902.jpg
Chuck
11-17-2009, 04:30
gilv_58

Chuck

Nice work!!!!! Those angles look great. What are you asking for them?

My mirror ultramount is 1 3/8" tall with the center of the hole for the mounting screw some 0.65" from the bottom.

Right now if I shine the laser beam straight to the galvo mirrors it hits some 0.08" low. I know I can take care of this with the mirror so I was planning on placing the mirror flat on the table and attaching it to the vertical leg of the "L" angle and placing the horizontal leg of the "L" angle away from the ultramount.

But the galvo block has the mounting screw holes at the bottom. So I am considering putting the galvo block up on a 1/4" plate. I will drill and spot face the bottom of the plate and run the screws up to the galvo block from the bottom. Then screw the plate, with the galvo block attacked to it, on the optics table after I drill and tap it.

The reason I am telling you this is because if I do this I will raise the laser by the same 1/8" which means that the mirror can me rasied by 1/4" or so. So your "L" may just be right height as they are.

I do have limited space and would like the horizontal bar of the "L" not to be much longer than 1" although if its too much work to make new ones I can live with the "L" angel sticking out of the optics table.

Let me know so I can get you the funds today or tomorrow as I want to keep moving on this project.

Thanks. How far are you from San Antonio anyway?
11-17-2009, 05:00
no-esc

Gilv,

I just wanted to say thank you for starting your thread on here. You have answered alot of questions I was starting to run into.

So thank you from another first time builder...

v/r

Len
11-17-2009, 07:33
gilv_58

Len

Glad this thread is helping. I feel silly asking such basic questions. I try a search first to make sure issues have not been answered. But there are lots to learn.

Thanks for your posts it makes me feel better about asking such basic questions that most people here must take for granted.

Hope you get a camera soon so we can see the progress of your build. I will try to post most milestones although I am gathering quite an album of pics. I may post them all on Flikcr.

I was surprised that there are no systems in this site's galllery.
11-17-2009, 08:18
Doc

Gil, they are not silly questions. If you don't ask a question; how are you supposed to find the answer to your query?

Asking questions and sharing knowledge is what seperates us from apes and it's better to ask a thousand "silly" questions than to make a thousand costly or dangerous mistakes :)

Ian

Quote:

Originally Posted by gilv_58

Len

Glad this thread is helping. I feel silly asking such basic questions. I try a search first to make sure issues have not been answered. But there are lots to learn.

Thanks for your posts it makes me feel better about asking such basic questions than most people here must take for granted.

Hope you get a camera soon so we can see the progress of your build. I will try to post most milestones although I am gathering quite an album of pics. I may post them all on Flikcr.

I was surprised that there are no systems in this site's galllery.
11-17-2009, 12:10
ElektroFreak

Definitely not silly. By you asking questions, now a new thread exists that will help others with their builds. More good information isn't ever a bad thing. Plus, you've got to start somewhere..
11-17-2009, 17:14
CRFultz

Gil they are 2.5" tall. The bottom of the slot on the Vertical is 1".
The Horz. is 2" but if you cut it in half there is still enough "fork" to mount to. I'm pretty sure the slot was milled for .25 bolt. They are painted with high temp flat black.
Anyway let me know where to send it. There's no reason to charge for it...call it a pay-forward:)
You said you needed one? That's correct?
Later
Chuck
11-18-2009, 04:09
gilv_58

Chuck

Thanks, check your IM. I think I can make these work. Yes i only need one thanks and I'll keep the "pay-it-forward" in mind, excellent concept!!

I am sure glad i found this board as it is full of people with experience and willing the share and not just knowledge!!

You and guys like laserman523, gottalovelasers, doc, electrofreak and others have truly contributed to my project. Thanks :D

I consider myself lucky to be part of this community.
11-28-2009, 16:05
gilv_58

3 Attachment(s)

Sorry for the long delay but there were many mechanical items I that to figure out. First I received an "L" angle from Chuck (CRFultz). I bought two 1/4' thick plates to rest the laser module and the galvos. Next I laid out he laser, the mirror and the glavos. You will can see the laser coming out on the "front" part of the plate.
11-28-2009, 19:12
CRFultz

Hey Gil,
If you need a smaller bracket just give me the measurements and I'll mill ya one. I work next weekend so I'll probably have a few things to make for my projector.

Chuck
11-29-2009, 16:39
gilv_58

5 Attachment(s)

Chuck

Thanks I'll send dimensions tomorrow.
I drilled the galvo plate and counter bored the bottom part to hide the screw caps. One hole I could transfer directly the second hole I transfered by measurements. SO its a little off.

By the way the Tap Magic cutting oil does a wonderful job. I highly recommend it.
11-29-2009, 18:51
gilv_58

2 Attachment(s)

Here are the galvos mounted on their base plate.

Next step to mount base plate to optics bed.

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