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9K views 18 replies 7 participants last post by  mafe 
#1 ·
motorized ceiling cord reel: preliminary calculations

So after considering the possibilities, tinkering with the numbers, considering the (said) potential hazards and comparing the price tags and user experiences that several of you guys reported on the related forum post , I decided to go the usual way for me: if children in China can make it, I can make it too.

Bottomline: If Matthias Wandel didn't do it already, I'll do it before he even thinks about it! =p

First order of business was to code a little software to make all the math with a pretty user interface, sliders and realtime graphics. Yay, I'm a computer geek too, so what the heck. With the software, playing with the parameters is a piece of cake to avoid potential problems (stacking of the cable when rewinding, etc)

In fact, the same system can be used for air tubing, and after seeing the prices of commercial units, I can sure make it for cheaper. I can even make it out of aluminium. But wood is better for the ecosystem.

So for this project to be, the data will be as follows:

Ceiling-mounted motorized electric cord reel

- holds 25' / 7 m of 3/4' (000AWG) / 10 mm tri-conductor power cable
- overall diameter: about 10" / 25 cm
- overall height (including exit cone): around 8" / 20 cm
- motorized function with either an RF remote control or a pull cord
- optional lights
- outer shape can be made pyramidal or conical, or even hemispherical and heavily inlaid with… whatever
- easy and cheap materials (plywood, small lazy susan bearing, $10 geared motor, $10 power supply with plenty of leftover power for overhead LED lights, a few plastic rollers from any DYI store)
- no need for fancy tools: printer (for the gear templates), bandsaw and circle cutting jig (or 3D printer if you have access to one), drill and bits, screws and screwdriver, minimal ability to read wiring instructions, can accomodate a beer or two
- one-weekend project or less.

Stay tuned for the prototype plan!
 
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#2 ·
Thomas great stuff,

the unit looks impressive and the way the cable

goes on the reel, makes more sense.
 
#6 ·
motorized ceiling cord reel: early plan and BoM

Here is a screenshot of the first prototype plan from top and side views.

Rectangle Screenshot Line Font Parallel


Full size here.

The overall dimensions are 11" height and 13 3/4" outer diameter.

Bill of Materials:
- plywood: TBD, scraps could do if you can make segmented turnings, outer shell can be a pyramid or a cone
- motor: $10
- power supply unit: $10
- Lazy Susan bearings: $4.50 plus postage (or get them at your local DYI store)
- misc electric stuff: depending on the command mode. If RC, add around $20.
- add the cord of course :)

so far, for the motorized function, we're around $40 give or take.

Time wise, I'll have to actually build it to be able to give a decent value, but this part will depend on the technique chosen for the cylinders (bent lamination of cheap veneer, segmented plywood turning, or even a mere octagon or other high facet count thing).

Now to end packing up for the 10 hour road trip tomorrow… TTYL
 

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#7 ·
motorized ceiling cord reel: early plan and BoM

Here is a screenshot of the first prototype plan from top and side views.

Rectangle Screenshot Line Font Parallel


Full size here.

The overall dimensions are 11" height and 13 3/4" outer diameter.

Bill of Materials:
- plywood: TBD, scraps could do if you can make segmented turnings, outer shell can be a pyramid or a cone
- motor: $10
- power supply unit: $10
- Lazy Susan bearings: $4.50 plus postage (or get them at your local DYI store)
- misc electric stuff: depending on the command mode. If RC, add around $20.
- add the cord of course :)

so far, for the motorized function, we're around $40 give or take.

Time wise, I'll have to actually build it to be able to give a decent value, but this part will depend on the technique chosen for the cylinders (bent lamination of cheap veneer, segmented plywood turning, or even a mere octagon or other high facet count thing).

Now to end packing up for the 10 hour road trip tomorrow… TTYL
Good luck on the long haul Soda … this is gonna be interesting for sure. I like the way you tinker.
 

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#9 ·
MagLight ;)

Quick post on improving the short-range working conditions in the shop: overhead fluo lights are okay but I'm getting old and need a boost when working close-in with the bandsaw or the drillpress. A smack in the forehead lead to this: I snatched one of my old spot lamps, got one of the computer drive magnets kept aside in a box, three screws, a chunka plywood, and a few minutes later I exclaimed: LET THERE BE LIGHT \m/

Gas Machine Engineering Machine tool Tool


Wood Art Fashion accessory Thumb Carmine


Lamp Gas Shelf Toy Machine


I like it so much that after a while I thought: F*k it, I'm gonna hack my bandsaw and DP and install fixed flexible light fittings on each one. And they happen to stock them where I work. Greatness in the workshop sometimes lies in small details. Hope it can inspire others ;)
 

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#10 ·
MagLight ;)

Quick post on improving the short-range working conditions in the shop: overhead fluo lights are okay but I'm getting old and need a boost when working close-in with the bandsaw or the drillpress. A smack in the forehead lead to this: I snatched one of my old spot lamps, got one of the computer drive magnets kept aside in a box, three screws, a chunka plywood, and a few minutes later I exclaimed: LET THERE BE LIGHT \m/

Gas Machine Engineering Machine tool Tool


Wood Art Fashion accessory Thumb Carmine


Lamp Gas Shelf Toy Machine


I like it so much that after a while I thought: F*k it, I'm gonna hack my bandsaw and DP and install fixed flexible light fittings on each one. And they happen to stock them where I work. Greatness in the workshop sometimes lies in small details. Hope it can inspire others ;)
Nice setup Thomas
 

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#16 ·
bandsaw inserts holder

Hi folks,
This completed project dates back to June 2016, I didn't find the time to post so here comes.
This is my bandsaw, small entry level but it really does the job with proper blades, of which I have several sizes and pitches. So I change inserts quite often. The factory insert was a crap piece of plastic, which I'm not going to show (too shameful), but here is one of my shopmade inserts in place:




And so I finally made the jump and built this blank inserts holder.



I did quite a number of plywood blanks, with the proper rabbet on the bottom so they can sit flush with the table, and quickly put together this MDF holder. It still needs a paint job though, I'll have to find a suitable paint!





I drilled and tapped for two M3 bolts to hold it behind the saw, and voilà! Very handy, when a new insert is needed. I keep the used ones with their corresponding blades.





If you've been looking for a way to store your blank inserts, well, this is the solution I came up with. Feel free to share your versions below!

Cheers!
 
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