Many of the corner brackets I made earlier split on me, so I am going to remake them. They all split in the same place where there was a lot of holes drilled through the same layer. I am going to make the blocks larger so that there is more glue holding each layer together. I am also going to put the set screws for the x and y rods through the top and bottom, so that they don’t remove a lot of material from a single layer. The set screw for the z rod must be horizontal, so I will make sure the hole for it is not in the same layer as the x and y rods.
I started with 7 blocks that were 56 x 56 and 1.5 inches thick. I marked one of them ‘Top’ and two each of ‘Left’, ‘Back’ and ‘Right’.
In each block drilled a hole for the x rods at (y, z) of (28, 26). This was drilled with an 8.4 mm bit all the way through the block. I drilled another similar hole for the y rods at (x, z) of (28, 12).
I drilled a hole through the center for the set screws. This is at (x, y) of (28, 28). I drilled this with a 4.2 mm bit all the way through the block. I used the tap set to thread this hole from the surface to the first hole it intersects. I threaded from both the top and bottom.
In the ‘Left’ and ‘Right’ blocks I drilled holes at (x, y) of (15, 15) and (41, 41). These were drilled with an 8.4 mm bit all the way through. In the ‘Back’ and ‘Top’ holes I drilled similar holes at (15, 41) and (41, 15).
Update: I had to drill a third hole from top to bottom for three of the corner brackets for the y-post-rod. Fortunately I marked all four holes so I just had to figure out the right one and drill it. Unfortunately, I had to disassemble the top frame to drill the holes. I also had to drill and thread a hole for a set screw, similar to the directions below.
Next I drilled set screws for the z-posts. In the image above I have drawn arrows parallel to where I drilled these holes. Each hole is at a z position of 19 and is 15 mm from the nearest corner. These were drilled with the 4.2 mm bit just until I intersected the z-post hole. I then used the tap tool to make threads in these holes.
The z-posts will protrude 39 mm below the corner brackets instead of the 42mm called for in the assembly instructions.
Update: Because these blocks are larger than the plastic parts would be the 8 x and y rods must be 512 mm instead of 500 mm. I tried putting everything together with the short rods and the bed just wouldn’t fit.