Mount your pieces on to a turntable. Where the turntables are synced togeher on the bottom by a belt or gears so that you can spin your pieces without worrying about alignment. Just align them the first time.
I used to work in a Tool & Die shop and we made dozens of these molds for the old rotary phones. The cavities had to be polished to a mirror finish for the final plastic part to be as smooth and glassy as they are. We would use a duplicator in the earlier years and make the cavity and core very same principal as your duplicator. Great job!
Dear Friend. I make this comment, but not fluent in English, I wrote this thanks to google translator, because I'm Cuban and since I came to the U.S. three years ago I have been fascinated as you get it all together using wood, am a carpenter, Cuba and we had to iinventar and make tools, I present my regards and my respect, teacher
Actually, by alignment, I was referring to calibrating out any error in making these. Just think of how many things could be subtly off by half a millimeter in what you describe.
i dont necessarily want to make the things that you have...but i am in awe of your skills.... i literally am glued to the videos and really...i just cannot get over what you do... amazing. love it. thanks for the ideas...dont stop....
Another inspiring and impressive video. The copy jig looks like a comparatively simple build given what it can do - amazing! I love the little iPhone joke at the end.
Have you ever thought of using this tool to make carved top guitar bodies? Like the ones made by PRS (they call it a violin carve)? There are plenty knock offs for cheap. Compared to this telephone it should be fairly easy to make. I really admire your work. Great channel!
You probably don't need it, but some hints for improved performance: 40mm dowel handles each side of the router/follower fixture. Line the roller rails with aluminium angle to improve lifespan and precision. Use a flat bottomed, round cornered bowl-bit instead of a hemispherical bit to avoid the problems associated with cutting at the centre tip of the round bit where blade tip speed becomes very small. Fit hydraulic dampers or brakes to each axis to minimise chattering or skipping.
I just bumped into your vid, very nice! I bought a duplicarver off Ebay a while back but have not had time to use it. Mine is more of a gunstock or table leg carver, yours is a little more practical. Thanks
hi Matt, to get the alignment right while repositioning the pattern and work, use 2 round discs for the mount and connect close to the circumferance them using a thin steel rod. this was rotating one disc will rotate the other. or you may use your gears to do the same trick :)
It would be cool to see if you copy carve those nice seat bottoms you see on older chairs. They're carved just right making a solid wood seat comfortable
Another good one. I have a question about the router you are using - is it powerful enough? I am thinking about buying another router for inlays and pattern carving, I am torn between the Bosch you are using and Porter Cable's 1 1/4 hp package. Any opinions? I am guessing the Colt would really do fine, and less mass to move around.
I was also concerned about your ears, Matthias! I can recommend ear protection with built in radio. I use them, love them, and they are just super relaxing to work with in loud environments. There's a big Swedish brand which produces them.
MatthiS......BLOODY AWSOME. The stuff you come up with is just amazing. Congratulations.... I would like to offer an answer to "Itnecap".......because he can. And obvoiusly enjoys a challenge. Sometimes you do things to expand your mind and your knowledge. Other times you just like the challenge.
Matthias, Have you tried to dampen the movement of the router with springs ? The speed of the router will force some degree of pull to which you will have to act against. Just a thought to make it less tiring. As for the reach of the router bit, have you tried an extension collet?
You could make a rotating base for both object and copy. As you rotate one, the other rotates as well. You could even make a tilting mechanism as well that would allow you to flip both pieces, always keeping them aligned. If you had those additions, you could just phone in a project like this.
The dust collector pickup on this project made me think of this, have you done a downdraft sanding table yet? Do you know of any good references on calculating the airflow vs table area vs. hole area in the table to achieve good airflow and dust containment ?
Love the woodworking videos! One word of caution though. I know of several woodworkers much older than you that are hating life and had wished they wore a mask when they were younger. Give it some thought if you don't.
You might be able to mitigate the reach problem by adding a tilt left and right ability with a parallelogram structure. It wouldn't have to be far, just a couple centimeters either way. Not sure how you would do it with the build you have right now, but it'd be neat.
That has been suggested many times, but it would be very challenging to make that work accurately enough. If you don't believe me, try it and you will see.
My parents gave me a wall-mounted western electric rotary phone by western electric. that looks like one that my dad grew up with, and I brought home a brown ITT touchtone desktop telephone from my cabin that the previous owner had, and my grandma and grandpa Oliver gave me their old rotary phone a western electric yesterday
I'm somewhat surprised you didn't have a system of gears installed so that the original and copy would rotate when you needed to do the front and back on the receiver, as apposed to spinning them manually. Exceptionally cool, but most of your vids fall into that category already, thanks for posting
For some angles it strikes me that you can't contact dead square for some cuts. Those kind of off-square cuts would mean your working into the hypotenuse. Did you observe any distortion or would this only be apparent in a larger piece?
Very cool jig! I imagine this would be a timesaver for gunsmiths duplicating/reproducting rifle stocks. Also, it would be interesting to see a large worm gear created/duplicated.
As usual, brilliance. But a suggestion for down the road: is there a practical way to get router bits made with extremely long shank ends for a machine like this to be able to do deeper detail work?
