Building the towers and assembling the frame:
|Completed Proteus Delta frame|
|12 tower gluing spacers, with 400% vertical scaling, freshly printed|
|Assembled jig with half of a tower clamped for gluing|
|Clamp in use, 2 inch deck screws used as fasteners|
|Closeup of tower half with tape measure for scale|
Next, remove the upper clamps, and apply epoxy to the exposed faces of the glue blocks. Put the upper tubes into place, it helps to have two people for this stage, then loosely mount the clamps, square the factory ends to each other, then tighten the clamps until things are just snug, it's very easy to snap a clamp if you over tighten things. Lastly, slide the end clamps on to keep things square, then leave to dry for 2-3 hours. Once dry, unclamp everything and repeat for the other two towers.
|Assembled tower drying|
|Finished frame parts waiting for assembly|
After all the gluing is done, finial assembly is simply a matter of inserting the towers into the corners of the bottom triangle and then putting the upper triangle on top, you might need to use a hammer to 'persuade' things a bit, but after everything is square and leveled, just use some 8-32x0.75 inch or M3x25mm screws and nuts to clamp things down and it's finished. I added a piece of 3/4-inch plywood to the top and bottom for extra strength, rigidity, and so I'd have somewhere to mount the power supply. I fastened the plywood on using half clamp brackets for 3/4-inch electrical conduit, 3 on the top, 6 on the bottom, they just snap into place and one screw is all that's needed to hold things securely. I've also added some light diagonal strapping on 2 sides using a couple pieces of air duct strapping.
|Nearly finished frame|
|half clamp for 3/4-inch electrical conduit|
With the frame finished, next up is building the rod arms and assembling the slider/carriage units.