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Chevy PW2

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Blog entry by apprentice posted 449 days ago 1074 reads 1 time favorited 19 comments Add to Favorites Watch

I’m not sure how this is going to work out online, here is the second Chevy in my plywood line up, in a much simpler layout, but just as reliable and very strong.

Birch Plywood is an ideal medium to use for this kind of project due to its multi layered higher density form, but you could use good quality exterior ply which is slightly cheaper if the former is unavailable.

First pictures straight out of CAD gives a view of the basic outline of what are basically a pair of side boards in Birch plywood at 3/4” or 18.00mm thickness here in the Uk. There are additional cut outs to be removed from the boards, so I will add shots of where these are situated later.

When creating any cut outs in the boards, make sure to pin them both together and establish a squared off corner and face edge to work from and take all your measurements from, this will ensure a matching pair for assembly later, don’t trust the manufacturers edges when purchased, measure twice cut once.

Picture above show a 3D line drawing of a tumbler, which can be made in aluminium or steel. Top hole is 10.00mm, bottom hole 14.00mm, body section 25.00mm by 20.00mm. Holes are 50.00mm between centres.

All sizes are marked in centimeters unless stated otherwise.

The new PW2 will incorporate a front closing vice as in the traditionally orientated Chevy with a manual quick locking cam/mech to hold the vice closed mid job, so you can leave your seat with the pack held firmly in situ.

As we progress, live photos and ammendments will be added where detailed assembly is needed.

First amendment to the side boards in blue screen, to allow a deeper pack to pass through, the pack gap is 4.5cm, the beauty of this design is the shaped can be drawn directly onto the plywood and visualised before cutting begins.

All constructive comments welcome.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded



19 comments so far

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apprentice

201 posts in 786 days


#1 posted 448 days ago

A few more 3D views of the final layout with the arms in situ, the front jaw of the vice will be fully floating and attatched to the top arm made from several layers of plywood for a very strong support.

The cut away below the lower arm is for the foot rest.

A bycicle chain is used once again for the connection of all parts and this time the adjuster is built into the top arm for easy adjustment.

There are less parts on this model, which is now DXF’d for CNC of all parts, which will take less than an hour to be made into a flat pack kit ready for gluing/assembly.

The tumblers are also CNC’d and in kit form ready to assemble.

I have worked out the optimum width of the body so it is comfortable to sit and work from, to suit all shapes and sizes, only one mod needs doing for varying heights of people, which can be done in PC before cutting begins, so this is a horse anyone can ride.

2 hours down time in CAD s far.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#2 posted 448 days ago

Side plate.

Floating vice jaw, free mechanism self supporting and very rigid, the fulcrums are orientated for high power at little energy needed.

The end boards of the main body are held in place with 10.00mm slots routered into the inner edged so the locate the full length of the sided and are then pegged top middle and bottom then held in place using standard pozi wood screws, same for the rear end board below the seat.

The rear vice jaw is one of the end boards.

The two cut out’s on the sides become the seat itself.

More 3D drawings coming soon, as an assembly which will set the scene of how it all works and self jigs itself for great strength.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#3 posted 448 days ago

Things should be getting a little clearer how everything fits together now, the front mid and back boards in situ in their slots and screwed together. The front and back board slots run right through and the mid board slots to the bottom of the vice/pack gap.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#4 posted 448 days ago

Above showing a CAT scan of the main components, only 10 main parts make up the body and vice, all parts are made from plywood, bar the pivot pins/axles.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#5 posted 448 days ago

Final rigidity is gained via the seat being tenoned into place, the front leg cross brace and the tjree main metal pivot pins, the whole structure is self jigging for easy assembly and can be taken completely down for storage or shipping.

That is the basic outlay done, now I will build and amend as is needed, the next stage is the real thing in wood and more pictures.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#6 posted 447 days ago

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apprentice

201 posts in 786 days


#7 posted 447 days ago


That is the CAD Model and Mk2 done, now for the physical reality to begin next week, as far as I can see electronically everything fits where it should, any alterations I can show with live photos.

If anyone has any questions please ask.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#8 posted 446 days ago

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apprentice

201 posts in 786 days


#9 posted 446 days ago

Saw frame limbs 50.00 X 25.00mm, Back brace 65.00 X 25.00mm to allow for extra depth to incorporate built in haunch.

Saw frame total length 500.00mm inside length 45.00.

Total width 310.00, enough inside area for the longer blades available today, for shorter blades lengthen the blade holders.

Blade holders 10.00mm bar.

Frame/sliding rod mounts are 20.00 X 20.00mm X 80.00, spigot holed to rear of frame 20.00 round 20.00 deep, centres are 80.00mm from outer edge of frame.

When joints are glued and dried, use 2 X 8.00mm wooden pegs across each joint to prevent creeping, also place 10.00mm bar through both of the blade holder holes to keep things properly in line.

Two types of blade holding mechs coming soon.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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Mauricio

6799 posts in 1778 days


#10 posted 436 days ago

Oh now I get it! I’ve been wracking my brain trying to figure out what a chevy is. Its a Chevalet!

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

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apprentice

201 posts in 786 days


#11 posted 435 days ago

Likewise, I have been trying to remember the name for the type of angled joints you used on your bench, now I remember, its a technique called Joyned.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#12 posted 412 days ago

With the good weather and longer days I gathered all the materials and started the PW2, three days later the body and vice is done. I opted for the cheaper but longer route of hand routering the body out. Not a gery good photo of the main body, but it shows the basic concept of the traditionally oriented vice and jaws.



A few more shots of the vice layout, front half has a removable tip and the rear is adjustable for taking thicker packs if needed.

Showing the simple but very strong box slotting ioints, no glue, just screwed together.

One piece saw frame in birch ply, very stiff indeed even at 18.00mm thick.

On this version I’m going to try and devise a single internal locking cam, to lock the trans arm.

The vice is closed using the heels on this version like the vintage model and works really well indeed, lots of knipping power tor very little effort.

Trans arm and saw coming soon, with a twist.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#13 posted 412 days ago



The vice can be opened fairly wide for lifting in larger packs, and the seat slides backwards and torwards for different users, the vice is also adjustable for different heights, seen here at it 6 foot.

There is an adjuster on top of the chain so the foot pedal can be fine tuned for different feet positions.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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apprentice

201 posts in 786 days


#14 posted 412 days ago

Showing vice fully open, and internal mech and chain.

-- http://www.youtube.com/watch?v=qcyhgsGA6mY&feature=player_embedded

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Mauricio

6799 posts in 1778 days


#15 posted 411 days ago

Wow! Nice!

-- Mauricio - Woodstock, GA - "Confusion is the Womb of Learning, with utter conviction being it's Tomb" Prof. T.O. Nitsch

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