HUGE Shapeoko XXL Upgrade - Frankenpoko CNC Router

In this video, I'll show you how I built a custom frame and stretched my shapeoko to 57 inches long! We'll add a set of standard length rails to my XXL and use t slot structural framing (80/20) for the frame.
**These links no longer seem to work. Try reaching out to the company to see if they still make them.**
Rail extensions - www.3dtec.us/product-page-1/c...
Riser Bracket - www.3dtec.us/product-page-1/c...
Support Bracket - www.3dtec.us/product-page-1/c...
Did you build one of these after watching this video? If so, I'd love to see it! Please tag me on Instagram @full_steam_designs and Facebook @Full Steam Designs
___________________________
Watch list:
Faster Bit Changes - • Better than a touch pr...
How to Adjust GRBL Settings - • How to speed up your S...
___________________________
Tee shirts:
teespring.com/full-steam-desi...
teespring.com/full-steam-desi...
/ fullsteamdesigns
/ full_steam_designs
fullsteamdesigns.com/
If you enjoy my content and would like to show your support on a more personal level, please consider checking me out on Patreon. Thank you!
/ fullsteamdesigns
Or you can buy me a coffee: www.buymeacoffee.com/ChrisPow...
Another great way to help support the channel is through my Amazon store. I get a small kick back from anything purchased. It’s full of products that I use and recommend. www.amazon.com/shop/chrispowe...
___________________________
I get a small kickback from the following affiliate links. You get the same great price, but can help the channel grow by using these links.
10 meters of 9mm wide belt - amzn.to/3wHEsvK
4545 t slot framing - amzn.to/3bX5irZ
Corner brackets - amzn.to/3uxf8qM
T bolt - amzn.to/3yPLqB0

[@lanelauhoff]

This is pretty rad. I'm looking forward to the calibration video!

[@KR4iD751]

Hell yeah! Was anticipating this video all week! Cheers!

[@ChrisPowellFSD]

Thanks! Glad I was able to get it done by the weekend

[@lprondzinski5678]

Excellent job! Thanks for sharing.

[@brendaboyce9967]

Amazing work! Love your machine logo. Very original!

[@ChrisPowellFSD]

Thank you

[@wafflebeaver]

Well done Chris. You made this look super easy though. It makes me think I should get a used CNC and do this upgrade

[@ChrisPowellFSD]

Thanks. Do it!

[@JohnColgan.]

What a beast, not quite big enough for full sheet of plywood, but I can imagine flattening a wasteboard be massive task. The SH4 T-Slot rails looks about best plan for wasteboard, will give you flexibility for holding material. Can't wait to see what you build on this.

[@ChrisPowellFSD]

Thanks. I ended up doing a t slot wasteboard. Surfacing wasn’t too bad. I like to push stuff pretty fast when possible. I still haven’t gotten around to any big projects. Hopefully I will soon. Here’s the t slot/wasteboard video. kzbin.info/www/bejne/d3jRYaWIo897l7M

[@willefrieden1]

Amazing work!

[@aweirdguynamedjeff]

Fantastic upgrade! 👏👏

[@ChrisPowellFSD]

Thanks!

[@Izarius197]

You made the upgrade look So Easy and we both know it wasn't! Congrats man. Only a few months into my xxl and wishing I had just a few more inches most days.

[@ChrisPowellFSD]

Ah it’s not so bad. It’s like a big erector set lol

[@imowens6858]

That’s what she said

[@taciolps]

Good Morning I loved the design modification.

[@ChrisPowellFSD]

Thank you

[@gilbertresto4060]

I love what you did, I will be reaching to you for assistance soon. I will be supporting your channel.

[@ChrisPowellFSD]

Thank you! Reach out anytime

[@davidjennings2733]

Chris, Awesome job and you coming out to Texas anytime soon, lol.. I am getting ready as in tonight and purchasing the XXL expansion kit and would like to just add the Y rails to the existing Y rails. Making it much larger than just the XXL. Thanks again for putting this up and sharing your experience.

[@ChrisPowellFSD]

Haha probably not. Let me know if you run into any issues. Good luck.

[@karlriley1314]

Looks HUGE.

[@TenmaFN]

Awesome Chris!

[@ChrisPowellFSD]

Thanks!

[@valcourtarts2955]

great work!!

[@ChrisPowellFSD]

Thanks!

[@gerrykavanagh]

That is so overbuilt and I love it. Really interested in 15mm belt mod when you get round to it.

[@ChrisPowellFSD]

I can’t wait to get the parts. Should be a great addition.

[@gerrykavanagh]

@@ChrisPowellFSD have you taken a look at the new Shapeoko 4XXL? I wonder how many of the mods can be lifted over to the S3? The new v-wheels would be interesting as well as the 15mm belt.

[@slackersoftworks6242]

Man I've seen your post on the carbide Facebook page Ive been waiting to see how you went about doing this. I have the xl rails after upgrading to the xxl kit I want to do the upgrade also, but the main thing Ive been wanting to upgrade the belts to 15mm thanks for the video its built like a tank!

[@ChrisPowellFSD]

Thanks. I hope I get those parts soon

[@armychris3973]

Do you know where the cut sheet is for the tslot rails

[@derekslifer7774]

Absolutely Genius!!!

[@ChrisPowellFSD]

Thanks!

[@JANDLWOODWORKING]

OMG I LOVE IT!!!!!!!

[@jeremylawson6648]

thanks for this

[@bryanharness1122]

Awesome!

[@ChrisPowellFSD]

Thanks

[@shaneduncan4888]

Hey brother love what you did in this do you have a complete guide how you did it I'd love to do this to mine

[@shaunm2208]

Thank you sir

[@ChrisPowellFSD]

Thank you

[@anthonywindle7503]

Awesome build. I have the xxl upgrae for my xl. Where did you get the front and rear brackets made?

[@bentebrunsvelt319]

Verry good👍👍

[@ChrisPowellFSD]

Thank you!

[@upnorthoffcuts929]

This is something that I needed to see. Thought I was going to have to get a new machine when I move back to Michigan because I was wanting something larger. So you maintained the 32" on the X but what was the total on the Y in inches? And also can you extend the X axis? Great video thank you for this.

[@ChrisPowellFSD]

You could, but would have to rely on just the coupler to support everything.

[@skrilla_skanttv402]

Hey Chris, love your work keep slaying and being great my brotha..😁🙌 by chance will you have the build plans , cut list measurements for this build up on your website soon?

[@ChrisPowellFSD]

I keep forgetting. I’ll try to get it posted tomorrow.

[@skrilla_skanttv402]

@@ChrisPowellFSD awesome, thanks bro 🙏❤️

[@ChrisPowellFSD]

Ok they’re up. Hopefully it’s not too confusion. Fusion was fighting me the whole way. Don’t forget, this is 45mm extrusion. fullsteamdesigns.com/maker-resources/

[@skrilla_skanttv402]

@@ChrisPowellFSD hey, Chris I was looking at the plans on your website ? So it’s (12)Pieces @ 64” for the frame & braces and (6) Pieces @ 32” for the legs plus the (4) -2” legs lifts

[@Todd-W]

Chris, nice build man.. might need to fool with the $130 and $131 values to make it home correctly.

[@ChrisPowellFSD]

Thanks I’ll look into those.

[@nicktucker4916]

I upgraded my ShapeOko to the XXL and was looking at the left over extrusions... This gives me some food for thought :) What collet are you using in the Dewalt?... Looks way better than stock!

[@ChrisPowellFSD]

I was lucky enough to be able to buy someone’s old pieces. Fortunately they sent me all of the extras too like the drag chain and wiring. It’s a great start to the project.

[@jeanpierrepotvin7957]

Nice 👍

[@ChrisPowellFSD]

Thanks

[@davidfranklin1789]

This came out badder that FFUUUUU! Do you have a build list or plans?

[@ChrisPowellFSD]

Yes they’re on my website.

[@jeremylawson6648]

Do you think there’s a way around this with other parts besides the store that’s no longer supplying them?

[@gregbrown9480]

Incredible Chris! Ive been wanting to try this for a long time! What was your final build cost?

[@ChrisPowellFSD]

I figure about $600, but I did get the extrusion pretty cheap.

[@gregbrown9480]

@@ChrisPowellFSD oh wow that much less than I thought. Where were you able to get the extra y rails?

[@ChrisPowellFSD]

I bought them from someone in the Shapeoko Facebook group.

[@dpierovich]

I’m doing the Frankenpoko upgrade to my XXL and was interested in whether you ever did the 15mm belt upgrade?

[@ChrisPowellFSD]

I still haven’t gotten around to it. No issues with the 9mm belts yet, but it is still something I’d like to do.

[@rogerrippeon7450]

In your vid you're using double hole 90* brackets, but the link you posted are singles... Any qualms with using the singles over the doubles? Or was that just a wrong link?

[@ChrisPowellFSD]

It’s just what I had. Not sure the extra strength is needed.

[@dmnchild]

This is great and all, but the shirt man.. The shirt.. I need that.

[@ChrisPowellFSD]

It’s from AvE. If you like the shirt, you might like his KZbin channel too.

[@btowniron2237]

This is awesome how much would you say roughly it cost you for the conversion? And where did you purchase your structural framing?

[@ChrisPowellFSD]

I got a bunch of it from an auction. Saved me a lot of money doing it that way. I’d say about $600 into the whole upgrade so far.

[@9sparkfuls]

love it. I think it would be more like $1200. Just the 45mm Al is ~$6/ft retail.

[@ChrisPowellFSD]

Yea it’s not cheap new. I see stuff pop up on the cnc Facebook groups from time to time. It’s out there. Just gotta find it.

[@joedavidson9159]

I am in desperate need of a large cutting surface. Do you have an actual parts list of what is needed to build?

[@ChrisPowellFSD]

There’s a diagram on my website. fullsteamdesigns.com/maker-resources/

[@taciolps]

Can you tell me the description of the aluminum structural profile that you used to enlarge the Y axes?

[@ChrisPowellFSD]

The piece used to connect them? There’s a link to the companies website in the description.

[@bmor02]

where you purchase the second set of rails for the shapeoko xxl?

[@ChrisPowellFSD]

I bought them from someone who upgraded their standard to an xxl.

[@hortontreevideo]

Do you have the measurements for the top rails and legs

[@ChrisPowellFSD]

63.625 for the top rails and 22.5 for the legs. Really they can be whatever height you want to get it to the height you need.

[@flyingfranklin]

This is an awesome build! I upgraded to an XXL from a SO3 so I have the rails needed for this upgrade. Any chance you have a cut list for the extrusions required?

[@ChrisPowellFSD]

I still have to put it together. I’ll post it on my website when it’s ready.

[@Th3mast3r69]

I wonder if carbide 3d would have been willing to just sell some double long extrusions

[@ChrisPowellFSD]

They’re not

[@dennyscnc]

Did you ever upgrade to 15mm belts? If so did you make a video. I am looking for 15mm belt anchors

[@ChrisPowellFSD]

No I never ended up doing it.

[@loganbrantley7216]

Maybe you explained this but if the Shapeoko XXL has a 33in x 33in cutting area and you put 2 rails together why isn't your new cutting area 33in x 66in?

[@goodwinml]

Do you have a material build spreadsheet for parts? How many sticks of extrusion did this take?

[@ChrisPowellFSD]

I’m going to put one together and put it on my website.

[@goodwinml]

@@ChrisPowellFSD , cool, can't wait.

[@blake102989]

Is there a reason you didn't do the x axis? I ask because I just got my xxl upgrade kit today and was wanting to do this with my old standard parts

[@ChrisPowellFSD]

There’s no way to add an additional support to the x axis.

[@blake102989]

@@ChrisPowellFSD couldn't you run a piece inside and a long bracket across the back of them?

[@blake102989]

Or even a U shape piece of steel or aluminum over the back side? Just some thoughts that could possibly work I may try

[@shaunm2208]

Hi Chris, i tried the link for the extrusion and no luck, do you know if they still sell it.

[@ChrisPowellFSD]

Try emailing them. They might still be able to make them.

[@gregorysmith3225]

Chris did you ever upgrade your belt size?

[@ChrisPowellFSD]

No, I didn’t

[@eggdome787]

So did this make your overall cutting size to be 57in, or overal length cause the latter seems to make more sense. I’m looking at trying to get a Y cut around 60in so this would be perfect 👌🏻👌🏻

[@ChrisPowellFSD]

Cutting size. It has 1450mm of travel, but that’s with a little overhang in the front.

[@eggdome787]

@@ChrisPowellFSD that is just amazing. Any idea if this same concept works for S4?

[@ChrisPowellFSD]

@@eggdome787 I’m sure you could make something work. Just not sure if it’s as cost effective with the waste board they use. The frame/wasteboard was always a weak link with the shapeoko 3. They fixed those issues with the 4.

[@eggdome787]

@@ChrisPowellFSD for what I’m thinking of doing and the projects I have in mind for this size of a Y axis I wouldn’t be cutting through the materials into a waste board so I can build my own table. I did read that they won’t do upgrades cause of the new waste board system tho

[@ChrisPowellFSD]

@@eggdome787 I wish they would sell the pieces for the wasteboard seperate. Those channels look nice.

[@authenticwood5219]

Sold mines for the pro but this makes me regret it... I think. I really need to be able to fit a whole sheet on the bed... u think this is capable with the pro?

[@ChrisPowellFSD]

It would probably be a little more difficult/expensive due to the linear rails.

[@dennismacwilliams196]

What was the coust of this build if you don't mind. ? It looks so Awsom

[@ChrisPowellFSD]

Thanks. I got the extrusion second hand, so everything only cost about $600.

[@dennismacwilliams196]

Awesome Thanks, If that was wood it would be Close anyway.

[@bryanharness1122]

Hey Chris what machine should I get? Shapeoko pro, onefinity or cnc4newbie new carve?

[@ChrisPowellFSD]

I’m kinda liking that Onefinity x50

[@bryanharness1122]

@@ChrisPowellFSD appreciate it. I'm learning as much as I can from your vids before buying. I'm gonna get some software and start designing stuff and learn it as much as possible first. Appreciate all the vids been a great help

[@nyerby]

Will Carbide sell just the rails and not an upgrade kit?

[@ChrisPowellFSD]

Unfortunately no. I’m working on finding another option.

[@davidbissonnette4674]

I know this is a slightly older video but links do not work. Im about order my shapeoko soon and would like to get extensions for it.

[@ChrisPowellFSD]

Reach out to the company and see if they still sell them

[@davidbissonnette4674]

@@ChrisPowellFSD thank you

[@dylandesmond]

I have the shapeoko XXL, your website says shapeoko 3? Is this the same CNC? I would love to purchase this for bigger projects

[@ChrisPowellFSD]

Yea it’s a Shapeoko 3 xxl. Now they have a 4 and Pro.

[@dylandesmond]

@@ChrisPowellFSD Yeah I have the pro, just finished assembly and testing, hitting 8metres a minute on hardwood with Makita router running at max with no chatter on the bit they sent with the machine

[@dylandesmond]

@@ChrisPowellFSD will this kit go on a pro also? I have enough room to use a whole wall which would be great as I could put up a sound barrier as I have a lot of left over perspective plastics

[@hillbillyofsorts4111]

Where can i buy all the parts less the stand?

[@ChrisPowellFSD]

There’s links for everything in the description.

[@jeremykramer7021]

Do you know of anyone still selling the extension kits?

[@ChrisPowellFSD]

Not anymore. Carbide stopped selling them.

[@1804Neg]

Great work. Do you do commission work?

[@ChrisPowellFSD]

I’m sorry, I don’t

[@1804Neg]

@@ChrisPowellFSD Can you tell me where I can get the extrusion aluminum rails ?

[@sergiocarlon5559]

U don't want to sell it.?

[@kennethspivey9530]

Chris...I have the xl and want to upgrade my rails. Do u know of anyone that has a set of xxl rails that their not using and want to sell.

[@ChrisPowellFSD]

Sorry, I don’t. Try making a post on the shapeoko group on Facebook. Xxl rails might be a little hard to come by though.

[@ChrisPowellFSD]

You could just buy the upgrade kit from Carbide 3d. That will come with longer wires and belts too.

[@johncarr123]

Design a vacuum table for this rig.

[@ChrisPowellFSD]

I had thought about it. I just did t track for now. I might add some small vacuum attachments down the road.

[@antonioescobedo6930]

Links no longer active 😞

[@ChrisPowellFSD]

Reach out to the company. They might still make them and just not list them on their site.

[@smawhorter]

I see that you reused those god-awful L shaped belt clips (although you did route a channel on the back side to allow for adjustment). Did you consider another way to attach and tighten the belts (maybe a channel to pass the belt through and have the tensioner be on the back side of the plate)?

[@ChrisPowellFSD]

I’ll be upgrading to 15mm belts. This is just temporary.

[@smawhorter]

@@ChrisPowellFSD I'm upgrading to 15mm belts as well...curious to see how you address it.

[@armychris3973]

I can't find any of the parts you used. The links are no good.

[@ChrisPowellFSD]

Reach out to the company. They just might not list them anymore but can probably still make them

[@armychris3973]

@@ChrisPowellFSD Hey Chris, they are making them for me, thank you. I can't find the cut list for the tslot?

[@ChrisPowellFSD]

@@armychris3973 fullsteamdesigns.com/maker-resources/

[@JonValtandtheEvilRobots]

Realizing now that when I need a larger CNC machine, that I won’t actually need a larger CNC machine.

[@anthonywindle7503]

Awesome build. I have the xxl upgrae for my xl. Where did you get the front and rear brackets made?

[@ChrisPowellFSD]

Thanks. I got them from 3D tec. There’s a link in the description.

[@anthonywindle7503]

@@ChrisPowellFSD I used your links and bought the kit. You are the man! I can't wait to put it all together.

[@anthonywindle7503]

order #10030