Professional Documents
Culture Documents
A Base(I) 34x 42 - % Ply. 0Stylus Clamp (I) %xl%-3Y 2 (6) %" x 36" - Y I6"-thickAluminumfor Clamps
B Work Platforms (2) 12x 18- % Ply. P StylusArm (I) I "-dia.x 20" EMT Conduit (2) 3"-dia. Hose Clamps
C Feet (4) % x3-3Y2 Q Router Arm (I) I "-dia. x 28" EMT Conduit (I) Y 2"-dia.x 8" Alum. Rod for each Stylus Body
D Risers (4) I Y2 x 2% - 7Y4 R Counterweight Shell (I) 3"-dia.x 7" PVC (I) Y 4"-dia.x 12" Steel Rod for Stylus Points
E Side Rails(2) I "-dia.x 32" EMT Conduit S Counterweight Core (I) I Y 4"-dia. x 7" PVC (8) #8 x I Y4" FhWoodscrews
F Short Carriage Beds (2) I%x 3 - 10 T Counterweight Ends (2) % x 3Y a"-dia. (6) #8 x %" FhWoodscrews
G Short Carriage Sides (4) % x 2% - 5% (2) Yt-20 Threaded Inserts
H Wheel Retainers (6) I YI6 x I - 5 (8) #8 x 2" FhWoodscrews (2) Y4"-20 Knobs wI I Y4" Stud
I MainRail (I) I "-dia.x 37" EMT Conduit (IS) 115/16"-dia.Wheels (2) 5/16"-18x 2" Carriage Bolts
J
Long Carriage Bed (I) 1% x 3 - 20 (32) \ tA " x I Y4" LagScrews (2) 5/16"Washers
\._
K Long Carriage Sides (2) % x 2% - 15% (12) \ tA " x 2" LagScrews (2) 5/16"-18Hex Nuts
L Tool Support Core (I) IY ax4-ISY 2 (44) \ tA " Washers (I) 5/16"-18Knob wI I Y2" Stud
M Tool Support Top/Bot. (2) 4 x I 5Y2 - '/4 Ply. (16) 51t6"x 2" LagScrews (4) #6 x %" FhWoodscrews
N Clamp Blocks (2) '12x2-3'/2 (I) 5/16"x 12" Steel Rod for Axles
19
Materials & Hardware
~ LARGE BASE CAN
'---- BE CLAMPED TOANY
WORKSURFACE OVERSIZE HOLES IN RISER
FEET ALLOWADJ USTMENT FOR
SMOOTH CARRIAGE TRAVEL
PAIROF SHORT
CARRIAGE ASSEMBLIES
PROVIDEFRONT-TO-
BACKTRAVEL
RAILS ARE MADE FROM
l"-DIA. EMT CONDUIT
RISERS ALLOW
CARRIAGE
ASSEMBLY TOBE
RAISED OR LOWERED
DEPENDING ON
HEIGHT OF CARVING
STYLUS POINT
MATCHES SHAPE
OF ROUTERBIT FOR
ACCURATECARVINGS
SHOP-MADE CLAMPS ARE
MADE FROMALUMINUM
(REFER TOSHOP SHORT
CUTS ON PAGE 28) a
INEXPENSIVECONVEYOR aI)
WHEELS MAKE FOR EASY _-/
CARRIAGE MOVEMENT
PVC PIPE
COUNTERWEIGHT
BALANCES THE
ROUTERFOR EASE
OF USE WITH
LESS FATIGUE
LONG CARRIAGE ASSEMBLY
LOCKS ROUTERAND STYLUS
ARMS PARALLEL FOR SIDE-
TO-SIDE TRAVEL
BOTTOMROLLER
KEEPS CARRIAGE
SECURE ON RAILS
Exploded View Details
OVERALLDIMENSIONS: 52D)( 31"W)( 14H(MINIMUM AREA REQUIRED)
-
notches and then rip the blank
down themiddle.
You'll use the drill press to
drill the pilot holes for the lag
screws that secure the rails, as
inFigure 3. Then, theband saw
makes quick work of removing
thewastetocompletetheshape.
Each riser is attached to a
square foot with screws. Over-
sizeholesused toattach theriser
assemblies tothebasearedrilled
ineachfoot.Theseholesallowfor
slight adjustments to ensure the
side railsareparallel for smooth
front-to-backcarriagetravel.
b.
RISER
SIDE
T 0/,6"
VIEW
~
PILOT
HOLE
SIDE
-0
I
RAIL
"I
_J w.
~
NOTE: DRILL10/,6"
THROUGH HOLES
IN FEETFORLAG
SCREWS
NOTE: DRILL
HOLES THEN
RIP ALONG
CENTERLINE
OF SLANK
more than a large rectangular
pieceof plywood.
The two work platforms are
meant to be replaceable. I've
found that the %" thickness is
suitable for most work, but you
can use other thicknesses as
needed to position the work-
pieces at the right height. A few
screws hold the platforms in
placeonthebase.
Risers. The four risers are
notched to hold the side rails.
There are two sets of notches
to position the rails at differ-
ent heights as needed. Figure 2
shows aneasyway tomakeeach
pair of risers fromarectangular
blank. After laying out the pro-
file, drill theholes that formthe
FRONrVIEW
FOOT
#8)(2" Fh
WOOD5CREW a.
SIDE RAIL
(1"DIA. )(32" EMTCONDUID
E
(~4")(3"3Yz")
20
Toaccommodate the amount of
travel required for therouter and
stylus, the duplicator requires
a large base. Sacrificial work
platforms hold the original and
duplicateworkpieces. Andapair
of siderails areattached to four
dual-position risers.
Therisers, rails, and platforms
work together to position the
router and stylus for carving.
Thegoal is tokeeptherouter and
stylusperpendicular tothework-
piecesfor thebest results.
Base&Platforms.Togetstarted,
you'll make the base and two
work platforms, as illustrated
in Figure 1. Thebase is nothing
base &
Risers
FRONrVIEW
~SASE
21
!Smooth.
Inexpensive
conveyor wheels
make ideal rollers
for the carriages
(refer to Sources,
page 51).
c.
theprocess I used toassemble the
carriage bed and sides.
Each carriage rides on four
wheels (right margin). A fifth
wheel underneath serves to keep
the carriage from lifting off the
rails. A pair of wheel retainers
and an axle secure the bottom
wheel to the carriage and rail
(Figures 4band 4c).
After cutting the retainers to
shape (you'll need a total of six),
drill the mounting holes at each
end. A hole through the sides
secures the steel rod used as the
axlefor the wheel.
Assembly. To assemble the
carriage onto the rails, install
the four upper wheels with lag
screws. Assemble the lower
wheel between a pair of wheel
retainers using asteel rod with a
little epoxy. Use the holes inthe
retainers as adrill guide to fasten
thebottom wheel to the carriage.
Now you can cut and attach
the main rail. Turn to page 28 to
make the clamps. Use the holes
intheclamps tolocatethescrews.
a .
SHORT
CARRIAGE
BED
SECOND;
GLUE AND
CLAMP
SIDES TO
BED
FIRST:
CLAMP
BLOCKS TO
SIDES OF
CARRIAGE
BED
lagscrews. Thesescrews formthe
axles for the wheels. A quick trip
to the table saw forms a V-notch
on the upper face for attaching
the main rail. You'll drillthe pilot
holes for the clamps later when
attaching the main rail.
The pairs of carriage sides are
also beveled to mate with the
bed. The drawing below shows
b .
MAIN RAIL
(l"-DIA. )(37" EMf CONDUIT)
I
Clamping Tip
Side Rails. All of the rails are
made from l"-dia. EMT conduit.
After cutting them tolength with
ahack saw, I used the weld line
as a guide for drilling the over-
sizeholes for the lagscrews (Fig-
ure lb, opposite page).
I attached the rails to the risers
before loosely attaching the ris-
ers to the base. You'll make final
adjustments after the carriages
are assembled and installed.
Short Carriages. The threecar-
riage assemblies share the same
construction techniques. You'll
make two short ones now and a
long one later. Figure 4provides
all the details you need.
The carriage beds are bevel-
ripped to form mounting sur-
faces for the wheels. Use the cut-
offstoposition thebed at thedrill
press for drilling pilot holes for
(lYle" x 1"- 5")
G
SHORT CARRIAGE
SIDE
(0/..")( 2~6"- ~4")
IFIGURE s;ft
, 14" x IV ." LAG
SCREW
WIWASHER
Aluminum Clamps
fromascrap pieceof T'-dia. con-
duit and ahardwood block with
aV-notchcut into it. After drill-
ingpilot holes intheblock, usea
socketwrench todrivelagscrews
and help bend thedamp around
thecurveof theconduit.
Shop
Short
Cuts
KNOCKOFF
CORNERS
WITH FILE
u
Our Shop
29
Stylus. Shape
the stylus point to
match the profile
of the router bit.
TOP
VIEW
TAPEJ
BACKER
BOARD
a .
SECOND:
FILE RODTO MATCH
PROFILEOF ROUTERBIT
- - -
- - -
- - -
- - -
- - -
BACKER BOARD
(91\6" x :3%" - 5314")
WIDE BACKER BOARD
KEEPS YOUR HAND
AWAY FROMTHE
SAW BLADE
Tocreatean accurate copy of an
object, the carving duplicator
(page18)reliesonastyluswhose
shape matches that of the router
bit. For alarger- diameter stylus,
you canshape theend of analu-
minumrodat thedrill press.
Forsmaller, morefragilestylus
points, I shape a length of steel
rodtofitintothealuminumshaft.
The steel is more durable than
thealuminum anddoesn't flexas
easily. Filethestylus toshape at
thedrill press and secure it into
acentered holeinthealuminum
shaftwith adab of epoxy.
shop-made
Stylus
While there isn't anything com-
plicated about making the try
squares on page 30, one task
presents a bit of a challenge.
That'scutting theslotinthehead
tohold theblade of thesquare.
The problem is that the head
pieces are fairly small. So I
needed away tohold eachpiece
square tothetablewhilekeeping
my fingers out of harm's way.
Thesolution I cameup with isa
two- piece pushblock. The draw-
ings at right show how it works
for cuttingeachsizeof trysquare.
A widebacker board serves as
ahandle toguide theworkpiece
across theblade safely.Thelead-
ingend holds thehead square to
theblade. As you can seein the
lower right drawing, the backer
is sized to match the thickness
of thehead of thesquare ( 9 1i6 "). I
alsorelievedthebackcomer fora
morecomfortablegrip.
Theother part of thepushblock
is ahardboard face. Its purpose
is to hold the workpiece firmly
against the rip fence. I applied
a strip of double- sided tape to
thebacker tokeep thepart from
shiftingduring thecut. (1
Push Block