I have been trying to solve some problems as I’ve perceived them with the Maslow default frame(s):
- The edges of the stock are generally considered unusable.
- Most frames are meant to support only one size of stock (i.e., 8x4), but I want to use 5x5 as well.
- I often needed to screw the stock to the spillboard to correct warped stock.
- It’s hard to load/unload stock.
This weekend, I finally am declaring “success.” Yesterday, I trimmed off a 1/2" border from an 8x4 sheet of MDF. Each of the 4 cuts had a tolerance of less than 1/8" across the entire cut. The corners were quite square… not perfect, but almost.
The solution is what I am calling the “Clamping Skirt” frame. There’s a full write-up, including gcode, plans, photos, etc. here. Aside from the frame, this also requires “overclocking” the Holey calibration.
I took inspiration from the metal tracks often used in woodworking benches to create a spoilboard with built-in tracks for clamps. Actually, this upgrade could be applied to just about any frame. It’s really the spoilboard that is the upgrade.
It’ll cost you about $150 in parts. You’ll need a working Maslow to cut out the routes for the tracks (~8 hours of cutting). Then, about 4 hours to assemble. The resulting spillboard is 10x6, and can support stock as small as 2’x2’.
You could clamp your stock directly on to the spillboard, but the clamps will impair your ability to reach the edges. Instead, I clamp a 10" skirt which actually supports the stock. I use scrap wood of the same thickness as my stock, meaning I get a perfectly flush skirt all the way around the stock.
To demonstrate the efficacy, here is a dogbone piece I cut from the very very edge of the stock. It fit perfectly, within 1/16" tolerance.