Black Beauty Build Log

Black Beauty Has Foaled!!!

gtj — Thu, 19 Jul 2018 19:21:32 -0400

I can't believe it's been a year and I'm not claiming complete victory yet but IT'S WORKING!

The Flex3Drive in my mount...

WBUXscv.jpg

The back panel...

e2qZLTJ.jpg

Extruder motor mounted horizontally. Still have to neaten up the umbilical.

CltG1mC.jpg

The part cooling fan should be to the left of the heat sink but I busted the mount when I was playing with XY homing and limits. :)

hqmC4yC.jpg

eHLuQpX.jpg

I still have to do some tweaking on the gantry but it's OK for now.

5UxEhsL.png

I still have to do a lot of firmware and slicer settings work as well as some hardware cleanup but I'm pretty happy.
As it is now though, if it weren't for the fans you wouldn't hear this thing printing at 70mm/sec from more than a few feet away. I could hear the old MPIII from the other room at 40mm/s.

Bill of Materials and CAD files for the printed parts coming soon.

THANKS TO ALL WHO GAVE ME IDEAS AND SUGGESTIONS!!!

Re: Black Beauty Build Log

gtj — Sat, 14 Jul 2018 12:03:51 -0400

YAY! I got the Flex3Drive and Printbite yesterday as well as dc42's IR sensor to replace the finicky BLTouch.
I also think I got my EMI issues sorted. I'm replacing the 18ga wires with 22ga shielded twisted pair.
Dare I be optimistic and say "I should be printing before the end of this weekend." ?

Re: Black Beauty Build Log

gtj — Fri, 06 Jul 2018 18:05:48 -0400

Well, I'm so disappointed in the Flex3Drive folks. It's been 2 months since I placed my order and it's still "processing". I did get an email from Jason 2 weeks ago saying he was working the order and was trying to ship by the end of that week. Haven't heard anything since. I sent an email last night asking to cancel the order if they couldn't ship today or Monday but who know if that will ever get read. Most of my earlier emails have gone unanswered. I guess I'll have to file a dispute with Paypal to get my money back.

Anyone got any other suggestions for an extruder setup for this size of a machine?

Re: Black Beauty Build Log

gtj — Thu, 05 Jul 2018 07:36:53 -0400

Quote
o_lampe
I wonder, if that's related to the ribbon cable connector between Duet and DueX? Where did you probe the endstop signal?

Right at the Duex5 endstop connector. I also examined the signal pin on the end of the cable with it disconnected. In this case, the board was supplying only 3.3v and ground. Without anything to terminate the signal, the noise was horrific.

Adding the filter caps helped a great deal but didn't eliminate the issue altogether. I left the motors on before I went to bed last night but found them off this morning. Looks like it went about 2 hours before it tripped. This was at 3.3v however. I'm going to try at 5v today. New motors should be here tomorrow.

Re: Black Beauty Build Log

o_lampe — Thu, 05 Jul 2018 01:57:15 -0400

I wonder, if that's related to the ribbon cable connector between Duet and DueX? Where did you probe the endstop signal?

Re: Black Beauty Build Log

gtj — Wed, 04 Jul 2018 19:00:15 -0400

Quote
dc42
Odd, the first one says the last reset was a software one commanded by the user. This could mean that M999 was sent, or the Emergency Stop button in DWC was pressed, or it restarted at the end of doing a firmware upgrade.

The second reset shows power up as expected.

The comment about M999 got me thinking... I think this is an endstop issue on the Duex5 and not limited to 2.0x.
I have 7 powered mechanical endstops. All purchased at the same time.
They are assigned to X Y U V W A B.
X and Y are just configured as real endstops for homing.
U and V are connected to E0:1 and W A B are connected to E2:3:4 on the Duex5.

E0:1:2:3:4 are all configured as trigger T2 to execute M999.

The 4 connected to the Duet2 perform perfectly at 3.3v with both 1.21 and 2.01b1.
The 3 connected to the Duex5, when it's configured for 3.3v, will cause almost immediate trigger when the Z axis (3 motors on the Duex5) is moved with both 1.21 and 2.0x.
When configured for 5v, it's stable on 1.21 but Z movement will eventually cause the triggers on 2.0x.

This caused me to start investigating more and I found this...

With the XY motors ON but the Z motors off, this is what one of the Z endstop 3.3v supply (chan 1) and signal pin (chan 2) look like...

RuKNcNT.jpg

With the Z motors power on, this is what they look like...

dEOxy3x.jpg

You can say it.... EEWWWWWWWWW!

The endstops for the XY motors look clean EVEN THOUGH THEY HAVE LONGER RUNS OF CABLE!

XizZRdX.jpg

Now, the XY and Z motors ARE different. The XY are 0.9 deg and the Z 1.8deg and although I don't have the spec charts handy, I'm sure the inductance and coil resistance are different. So, I'm going to replace the Z motors, however, placing a filter cap between signal and ground right at the Duex5 connectors does clean things up nicely. I'm going to try that and see if stops the false triggers before I get the new motors in.

Re: Black Beauty Build Log

gtj — Wed, 04 Jul 2018 08:57:49 -0400

Quote
dc42
Odd, the first one says the last reset was a software one commanded by the user. This could mean that M999 was sent, or the Emergency Stop button in DWC was pressed, or it restarted at the end of doing a firmware upgrade.

The second reset shows power up as expected.

The first one was with everything idle for at least 30 minutes. I was watching Netflix at the time and saw the LEDs go off. Maybe the reason isn't being written in this case so it's left over from a previous reset?

Re: Black Beauty Build Log

dc42 — Wed, 04 Jul 2018 02:27:05 -0400

Odd, the first one says the last reset was a software one commanded by the user. This could mean that M999 was sent, or the Emergency Stop button in DWC was pressed, or it restarted at the end of doing a firmware upgrade.

The second reset shows power up as expected.

Re: Black Beauty Build Log

gtj — Tue, 03 Jul 2018 22:57:43 -0400

Quote
gtj

Quote
dc42

Quote
gtj
BTW, 2.0 isn't stable for me at all. I get random restarts even with everything at idle. No errors, nothing.
Back at 1.21 everything's stable.

Can you try 2 01beta? It fixes a possible contention between two tasks. If it doesn't help, please run M122 after one of those restarts and post the software reset data and the stack trace.

Yeah, that's what I was running, sorry. I'll try again and do the M122.

Just had a reset. When it came back, the Duex5 wasn't recognized.

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.01beta2(RTOS) running on Duet Ethernet 1.02 or later
Board ID: 08DGM-95BNL-MGPSJ-6JTD8-3SS6K-11XHZ
Used output buffers: 2 of 20 (2 max)
=== RTOS ===
Static ram: 28476
Dynamic ram: 95892 of which 0 recycled
Exception stack ram used: 176
Never used ram: 6528
Tasks: NETWORK(ready,1612) HEAT(blocked,1336) MAIN(running,3656)
Mutexes: FilamentSensors(null) DHT(null) W5500(null) TelnetGCodeReply(null) HttpGCodeReply(null) Telnet(null) HTTP(null) SD1(null) SD0(null) DirSearch(null) FileSystem(null) Aux(null) USB(null) MessageBox(null) ToolList(null) SPI(null) Malloc(null) NetworkGCodeInput(null) NetworkGCodeInput(null) FileInfoParser(null)
=== Platform ===
Last reset 00:00:40 ago, cause: software
Last software reset time unknown, reason: User, spinning module GCodes, available RAM 6420 bytes (slot 3)
Software reset code 0x0003 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x00400000, BFAR 0xe000ed38, SP 0xffffffff
Error status: 0
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 33.5, current 34.4, max 34.8
Supply voltage: min 1.9, current 2.0, max 2.2, under voltage events: 0, over voltage events: 0
Driver 0: ok, SG min/max not available
Driver 1: ok, SG min/max not available
Driver 2: ok, SG min/max not available
Driver 3: ok, SG min/max not available
Driver 4: ok, SG min/max not available
Date/time: 1970-01-01 00:00:00
Slowest loop: 0.23ms; fastest: 0.06ms
=== Move ===
Hiccups: 0, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm 240, MaxWait: 0ms, Underruns: 0, 0
Scheduled moves: 0, completed moves: 0
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
=== GCodes ===
Segments left: 0
Stack records: 2 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is idle in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Slowest loop: 0.45ms; fastest: 0.02ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(1) Telnet(0)
HTTP sessions: 0 of 8
Interface state: 5
=== Expansion ===

After power cycle

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.01beta2(RTOS) running on Duet Ethernet 1.02 or later + DueX5
Board ID: 08DGM-95BNL-MGPSJ-6JTD8-3SS6K-11XHZ
Used output buffers: 2 of 20 (2 max)
=== RTOS ===
Static ram: 28476
Dynamic ram: 95892 of which 0 recycled
Exception stack ram used: 176
Never used ram: 6528
Tasks: NETWORK(ready,1612) HEAT(blocked,1336) MAIN(running,3664)
Mutexes: FilamentSensors(null) DHT(null) W5500(null) TelnetGCodeReply(null) HttpGCodeReply(null) Telnet(null) HTTP(null) SD1(null) SD0(null) DirSearch(null) FileSystem(null) Aux(null) USB(null) MessageBox(null) ToolList(null) SPI(null) Malloc(null) NetworkGCodeInput(null) NetworkGCodeInput(null) FileInfoParser(null)
=== Platform ===
Last reset 00:00:31 ago, cause: power up
Last software reset time unknown, reason: User, spinning module GCodes, available RAM 6420 bytes (slot 3)
Software reset code 0x0003 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x00400000, BFAR 0xe000ed38, SP 0xffffffff
Error status: 0
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 30.3, current 33.7, max 33.9
Supply voltage: min 1.5, current 1.7, max 1.7, under voltage events: 0, over voltage events: 0
Driver 0: ok, SG min/max not available
Driver 1: ok, SG min/max not available
Driver 2: ok, SG min/max not available
Driver 3: ok, SG min/max not available
Driver 4: ok, SG min/max not available
Driver 5: ok, SG min/max not available
Driver 6: ok, SG min/max not available
Driver 7: ok, SG min/max not available
Driver 8: ok, SG min/max not available
Driver 9: ok, SG min/max not available
Expansion motor(s) stall indication: no
Date/time: 1970-01-01 00:00:00
Slowest loop: 0.36ms; fastest: 0.06ms
=== Move ===
Hiccups: 0, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm 240, MaxWait: 0ms, Underruns: 0, 0
Scheduled moves: 0, completed moves: 0
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
=== GCodes ===
Segments left: 0
Stack records: 2 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is idle in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Slowest loop: 0.53ms; fastest: 0.02ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(2) Telnet(0)
HTTP sessions: 0 of 8
Interface state: 5
=== Expansion ===
DueX I2C errors 0

Re: Black Beauty Build Log

gtj — Tue, 03 Jul 2018 21:23:45 -0400

OK, I'm back at 2.01b1 and I direct cabled the power between the 2 boards. We'll see how it goes.

I'm also getting closer on the gantry twist...

abV7XKh.png

Re: Black Beauty Build Log

gtj — Tue, 03 Jul 2018 20:56:02 -0400

Quote
dc42

Quote
gtj
BTW, 2.0 isn't stable for me at all. I get random restarts even with everything at idle. No errors, nothing.
Back at 1.21 everything's stable.

Can you try 2 01beta? It fixes a possible contention between two tasks. If it doesn't help, please run M122 after one of those restarts and post the software reset data and the stack trace.

Yeah, that's what I was running, sorry. I'll try again and do the M122.

Re: Black Beauty Build Log

dc42 — Tue, 03 Jul 2018 20:40:14 -0400

Quote
gtj
BTW, 2.0 isn't stable for me at all. I get random restarts even with everything at idle. No errors, nothing.
Back at 1.21 everything's stable.

Can you try 2 01beta? It fixes a possible contention between two tasks. If it doesn't help, please run M122 after one of those restarts and post the software reset data and the stack trace.

Re: Black Beauty Build Log

gtj — Tue, 03 Jul 2018 20:30:06 -0400

Quote
dc42
It's not just the resistance, it's the inductance too.

Well, it's easy enough to change.
BTW, 2.0 isn't stable for me at all. I get random restarts even with everything at idle. No errors, nothing.
Back at 1.21 everything's stable.

Re: Black Beauty Build Log

dc42 — Tue, 03 Jul 2018 15:31:41 -0400

It's not just the resistance, it's the inductance too.

Re: Black Beauty Build Log

gtj — Tue, 03 Jul 2018 11:35:14 -0400

Quote
whosrdaddy
Sorry, above comment may seem rude! Forgot to say, awesome cabling job!

/Kris

Heh, no worries!

For flexibility I ran the power cabling for both boards back to the power supply but it is 16ga wire and I did check the resistance between the negative terminals on the 2 boards with the ribbon cable disconnected. It was below the measurement threshold of my meter. I also have taken IR images of the whole back panel with all 7 motors and the bed in full operation. I'll post those tonight.

Re: Black Beauty Build Log

whosrdaddy — Tue, 03 Jul 2018 10:16:43 -0400

Sorry, above comment may seem rude! Forgot to say, awesome cabling job!

/Kris

Re: Black Beauty Build Log

whosrdaddy — Tue, 03 Jul 2018 10:14:34 -0400

Your Duex5 cabling is wrong, you must use a short cable on directly going from the Duet V- to the Duex5 V-.

as stated in the documentation :

Important! You must have a reliable low-resistance connection between the negative (ground) terminals of the two VIN terminal blocks. Failure to do so may result in high currents flowing in the ground connectors of the ribbon cable and may cause damage to the Duet WiFi or Duex5. Preferably, make this connection using either solid core wire, or stranded core wire with ferrules of the correct size crimped on securely. Re-tighten the terminal block screws regularly for the first few days of use, to make sure there is no creep in the wires causing the screws to become loose.

Re: Black Beauty Build Log

gtj — Mon, 02 Jul 2018 20:29:05 -0400

Well, I haven't posted in a bit but that doesn't mean I haven't been busy...

Finalized the Z axis lower ends. This arrangement is much easier to adjust the alignment and mount the Z-high endstops.

1OBIkh6.jpg

And doesn't this look nice? 6mm MIC-6 build plate.

TrF4pwW.jpg

I moved to the Delrin Z nuts and they are super smooth and I mounted the plate the same way I did the glass, with Nylon bearing races. The one at the back center is fixed and the two front ones are sliding.

cUl5nHa.jpg

Got a little wiring done. Under the sleeving, the bed cables are 12ga silicone for the 120V heater and 16ga silicone for the thermistors and some lighting.

fJiFR7E.jpg

I lied. I got a TON of wiring done.

STUz6DZ.jpg

I'm a big fan of keeping the hot side hot and the cool side cool. To that end, all mains wiring is on the right side.

Top unit is a 14.5A 24v power supply.
Below and left are 2 SSRs. One for bed heat and one that turns on and off the 24v PS.
The small power supply is a 12v 5A always-on PS that ultimately delivers 5V to the Duet.
Far right are the bus bars for ground and neutral.
Both power supplies tie their V- to ground.

jcpVAqu.jpg

On the far left are the Duet2 and Duex5.
Just to the right of the Duet2 is a 12v-5v DC-DC converter. It supplies always-on 5v to the boards.
The Duet2 switches the 24v PS via the Aux PS pin on the external 5v connector.
I got a really good deal on a ton of 16ga CCA stranded wire. It's a little overkill but so what.

NZlfiFd.jpg

Oh yeah, the undercarriage LEDs are working.

quedufQ.jpg

I forgot to take pics of the bed heater but I will shortly. It's a single 1600w 500x500mm pad. It's about 30 seconds from cold and dark to a 60C surface temp. The mass of the plate makes a beautifully even IR image, which I forgot to save. I'll get that shortly as well.

The only thing I'm missing now is THE FLEX3DRIVE!!!

Did I emphasize that enough Mutly3D? :)

Re: Black Beauty Build Log

gtj — Wed, 20 Jun 2018 08:56:23 -0400

Yay on two counts...

My MIC-6 plate should be ready tomorrow.
I heard from Mutly3D and he's assembling my Flex3Drive order now.

I've also decided to switch from 6mm wide belts to 9mm wide belts. I just have to re-print the carbon fiber XY rail sliders.
I'm also re-arranging the Y leadscrews and verttical rails slightly to align them better.
More pics in the next few days.

Re: I can "Air Print" :)

gtj — Sat, 16 Jun 2018 11:05:21 -0400

Quote
o_lampe

Quote

I guess the glass IS a little wavey

If you want to find out if it's wavey or binding mechanics, you could rotate the bed. ( Maybe not, because you glued the bedholder to the glass )

Yeah I thought of that then thought "Duh". Anyway I've got the MIC-6 coming in next week.

Quote
dc42
It looks like you have a slight twist in your gantry too, unless it's the glass again.

Quite probably. I do need to disassemble the gantry and replace the bearings with the correct ones and it does look like the motor in the "high" corner might be lifting the belt slightly as the carriage gets closer to it.

Re: I can "Air Print" :)

dc42 — Sat, 16 Jun 2018 06:58:01 -0400

It looks like you have a slight twist in your gantry too, unless it's the glass again.

Re: I can "Air Print" :)

o_lampe — Sat, 16 Jun 2018 02:08:23 -0400

Quote

I guess the glass IS a little wavey

If you want to find out if it's wavey or binding mechanics, you could rotate the bed. ( Maybe not, because you glued the bedholder to the glass )

I can "Air Print" :)

gtj — Fri, 15 Jun 2018 21:33:41 -0400

Made lots of progress...

I found a local place that'll give me a 20" x 20" x 1/4" MIC-6 plate for $176. Should be ready mid next week.

I made a design change to the bottom end of the Z lead screws. Having a bearing block right above the motor was introducing wobble in the screw so I got rid of it. I also changed out the couplers because the rigid ones weren't grabbing the lead screw evenly which also contributed to the wobble. I'm a little concerned that the weight of the bed is now only carried by upper bearing and the motor but we'll see.

aTZHe64.jpg

I am also getting rid of the upper (min) Z endstops now that I've got the BLTouch working. It's just hanging off to the side now. I may use them as Z max endstops. We'll see.
You can also see that I had to shim the upper bearing block to get rid of more wobble. Now if I lower the bed all the way then raise it at 1000 mm/m you can see absolutely no wobble in the screws.

Dl2PKdx.jpg

The Duet2 + Duex5 wired up. The 2 motors connected to the Duex5 are actually the X1 and Y1 motors.

M2ZRtC1.jpg

I still don't have the Flex3Drive but I mounted the BLTouch in the center of the tool carriage.

xuQkyaD.jpg

Z homing using the BLTouch is working perfectly as is auto bed levelling and mesh grid compensation.
I guess the glass IS a little wavey :)

JJztvgp.png

I'm still tweaking of course but I can "air print" now.
I may change out the lead screw backlash nuts for delrin ones. Not that the backlash bits were needed anyway but they're not as tight side-to-side as I'd like.
I also have to change out the bearings on the XY sliders. I accidentally put ones in that float in the Z axis so the sliders wobble a bit. There's not enough weight to keep them flat. :)

Mutly3D where are you??? I need that Flex3Drive!

Re: Black Beauty Build Log

the_digital_dentist — Wed, 13 Jun 2018 15:59:21 -0400

It might be a better investment to go cheap on the bed plate and use mesh compensation for any unflatness in the controller. With a plate that size 3 points might not be enough to support it, depending on the layer thicknesses you intend to print.

Re: Black Beauty Build Log

the_digital_dentist — Wed, 13 Jun 2018 15:51:09 -0400

Are you having someone machine a plate for you? I can't imagine why a piece of aluminum plate would cost that much. The local Speedy Metals retailer sells 12"x12" x 1/4" MIC6 for $40 the last time I checked, so a 500x500 piece should be about 3x that. There are plenty of ebay suppliers who sell for about the same price.

I picked up the 13.5" x 15" x 8mm (yes, I know, mixed units) MIC6 plate that became the bed in UMMD for $15 at a local metals supplier who sells cutoffs for scrap price. See: [www.howardprecision.com]

Re: Black Beauty Build Log

gtj — Wed, 13 Jun 2018 15:38:37 -0400

Quote
the_digital_dentist
You can print PLA on unheated blue painter's tape for testing without the bed heater.

True.

I did my Flir analysis of the 1/4" tempered glass over lunch. The results were so dismal I'm not even going to show them. I managed to get a response on an aluminum plate just a few minutes ago but he quoted me $460 for a mic 6 plate which is not in my budget. :) He's exploring other alternatives with a flatness between 50 and 100 microns.

Re: Black Beauty Build Log

the_digital_dentist — Wed, 13 Jun 2018 15:09:57 -0400

You can print PLA on unheated blue painter's tape for testing without the bed heater.

Re: Black Beauty Build Log

gtj — Wed, 13 Jun 2018 11:37:38 -0400

Quote
the_digital_dentist
It looks pretty good. When will it be printing?

Thanks.

I had everything hooked up to the Duet2 last night (after I re-pinned 6 connectors I screwed up) and gave the XY axes a workout.
I have to re-route some cables though as the ones that come down the inside corners in the back are being hit by the tool carriage. I'll have to route them on the outside.
The Z axis will be tested today and I'll mount the BLTouch and probe the bed today as well. I hope.

I still haven't heard back from @Mutley3D on my Flex3Drive so I guess they're swamped. If I don't hear back this week, I'll try and mount a bowden setup temporarily.

I'm making final calls on aluminum plate today. I called 3 places early last week and all 3 said "We'll get back to you". None did. You'd think I was asking for gold plated aluminum. If I can't get responses from them, I'll go ahead and order the heaters tomorrow. I just don't want to stick them to the glass then have to pull them off again. Speaking of the glass...one other task for today is to use a heater I do have (not the correct size) and do a test with my Flir to see how evenly the glass heats.

So to answer your question... early next week maybe?

Re: Black Beauty Build Log

the_digital_dentist — Wed, 13 Jun 2018 00:04:32 -0400

It looks pretty good. When will it be printing?

Re: Black Beauty Build Log

gtj — Tue, 12 Jun 2018 18:33:49 -0400

Motors and idler pulleys mounted and connectorized.

PVQaNyP.jpg

Here's the new bed mount. These are 11mm ball ends for RC car linkages.

2b3X9vd.jpg

I printed 2 sliding races from nylon for the front 2 corners, The center back race is circular to anchor the bed. The front 2 races "point" to the center back one. Since they're at a diagonal, the bed can only move in a straight line from the center back to the corners which it can't do normally.

9kEwk1k.jpg

Cabling done

VFijjYd.jpg

Now it's time to connectorize the cables, fire up the Duet2, test the endstops, and test the motors.
Where did I put that fire extinguisher?

FNA8qAi.jpg

I'm still waiting on the Flex3Drive and I'm still trying to find an aluminum plate for the bed. For now I'll just stick to the glass. I don't have to mount the heaters until I get the Flex3Drive anyway. I do have the BLTouch though so I'll be mounting that and testing until then. The frosting on the glass is just a spray-on protective coating, FYI.

The one major thing I wish I'd done differently is putting the frame on 2 saw horses instead of a table so I could stand up inside it. It would have made things so much easier. I still feel like the guy who built a boat in his basement though. I need to find a permanent home for this thing.