In this article I am going to make the Z axis motor and bearing plates out of 1/2” aluminum.
Attach the templates to the stock as shown here.
Mark all the hole locations with a punch.
Use a 3/16” drill bit to enlarge the punch marks.
Drill the center holes on the bearing and motor mounts with a 5/16” drill bit’
Drill The four 11/32” holes in each mount.
Drill the eight 3/16” holes in each mount. These will help clear chips when making the 20mm cutouts.
I have also drilled out the center of the main cutout with the pilot bit of the holes saw.
Before drilling the larger holes, I remove the center plug from my drill press table. This allows the chips to freely fall through.
The large 1-5/8” holes are made. Note the clamps on the stock.
Repeat the process on the 20mm cutouts.
The side templates are attached to the stock.
The hole locations are marked.
The side holes are drilled out with a 3/16” drill bit.
I decided not to use the #6-32 screws with tightening nuts to secure the mounts.
I tapped the four holes on each mount with a #10-32 tap.
The finished mounts deburred and sanded with mounting screws.