|Project by PopsHuckster||posted 02-13-2015 03:03 AM||6721 views||145 times favorited||35 comments|
Been intrigued with some of the unique wall switch covers I’ve seen lately in mags and home good catalogs. After making one from a picture I saw, I thought it was time to do one of my own. I thought about those knife switches you used to see in the old Frankenstein movies they used to bring the monster to life. With the help of a program called “Gear Generator” I downloaded from the net many years ago for free, I set out to design. Once it’s sealed I’ll probably put it in the shop to turn the lights on/off.
I learned a couple things while doing this project: 1. I’m getting too old and shaky to cut out gears this small anymore. 2: The eyes aren’t as good as they used to be either. BUT it hasn’t stopped me from working on another design already… just not as mechanical.
this shows the 2 main gears and the rack assembly needed to convert opposite motion into action needed to keep the UP-On and DOWN-OFF action correct. Thanks Gear Generator.
Putting the lever up turns it’s attached gear CW, this turns the little idler gear (#@%#!!) CCW and moves the rack assembly up. With it’s attached plate and hole over the wall switch, it turns the light switch on.
Operating the lever down causes the small idler gear (@#&%!!) to turn CW and move the plate attached to the rack down, turning the light switch OFF. The bracketed symbols represent the frustration from cutting the small gear out… 3 times. I used walnut, BB and poplar for the build. Next switch cover? An emergency / fire alarm button to turn ON/OFF and dim a dimmer switch I now have in the computer room.
This is the wall switch that started the project. I saw it in a small catalog and decided to make my own version of it. Painted after this shot was taken.
Link to You Tube video of switch working: http://youtu.be/4X5khEA-gf4