The AirExchanger Bottom Base

The bottom base sits below the spacers.

Here is the drawing file I used to import into my CAM software.

It is in the EPS format as that is what I used to move the shapes from CorelDraw to Vcarve Pro.

The drawing includes both a .81” and 1” circle for clearing the collet on the router. You can use a 1” for most routers and up to 2.2KW spindles.

I used a piece of 8” x 10” x .093” polycarbonate sheet stock. These can be purchased at any home center.

In addition to the plate stock you will need a piece of waste stock. (see below)

You will also need 20, #6-32 x 5/16” machine screws.

I used a 1/8” up-spiral two flute end mill with a 5/8” cutting depth.

Note that I also do a full finish path at 18000 RPM. If your machine can control the speed just set it to 15000 RPM for all the cuts.

Shown here I have secured my sheet stock and backer board with a series of table clamps.

I used a piece of MDF, 8” x 10” x 1/2” as a backer board. Notice that this is the same size as the sheet stock I used for the parts.

I start by drilling the 24 mounting holes through the sheet stock.

I use a 7/64” drill bit to drill pilot holes into backer at each hole.

I add a piece of tape to set the depth I need to drill. Use one of the 5/16” machine screws to help.

A 6-32 x 5/16” machine screw is snugly inserted into the holes shown below. These will hold the base and cutouts in-place while it is cut.

Place the 6-32 x 5/16” machine screws into the holes shown here.

Don’t place screws into the holes that are not marked or your end mill may crash into the screw heads.

I then machine the inside cutouts and outside profile.

I remove the protective cover and use my finger nail to remove any burrs.

Your AirExchanger top base is complete. Set aside until you start the AirExhanger assembly process.