After a play in 3D CAD here is my prototype Chevy in the making.
She consists of a single sheet of grade C birch plywood 18.00mm for the main body, trans arms and internal levers, seat etc, and there is still a couple of square feet left over after all the parts were cut out.
So far the cost of materials comes to just under a hundred pounds for 99% of the materials, the plywood was £40.00 inclusive of tax. All the main sections were cut out acurately for me at the supplier at no extra cost.
I’m making the head unit similar to the traditional but slightly different, so it can be made without complicated joints for those like me without any planer/thicknesser or saw bench. I’m using a router and a bandsaw for the majority of the work, and I have opted for hand cut dovetails for the construction.
Picture above shows the one piece plywood body with the two halves split to show the internals.
The internals consist of two nylon pulleys an bicycle chain and an upholstery spring and three sections of 25.00mm aluminium tube which passes through the body and secured by a pair of R clips on each shaft for easy removal. I turned the pulleys by hand on the wood lathe to take the chain.
The chain travels from the middle of the vice/jaw, around the pulleys to the multi layer foot pedal and arm on the bottom.
Showing the spring sat in its groove to prevent it from wandering during operation.
The vice/jaw opens opposite to traditional Chevy’s, which opens when you depress the pedals with your heels, the vice holds the work nice and firm once you stop cutting, you can let go when you stop cutting.
The main transarm is fitted and passes right through the main body and its secured by a wooden cam to quickly lock up the arm itself, next post will show the arms made from plywood and dovetailed together.