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copy carver/duplicator 2.0

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Project by luv2learn posted 792 days ago 12801 views 23 times favorited 16 comments Add to Favorites Watch

Well, I abandoned the dual purpose 3D pantograph/1 to 1 duplicator even though it functioned O.K. in favor of a copy carver/1 to 1 duplicator. All I did is remove the 3D pantograph mechanism and build a copy carver mechanism using the same gantry framework to mount it in.

I chose to carve a hammer for my first copy carver project. It seemed appropriate since if it didn’t work as envisioned the hammer would be close at hand to make adjustments.

Photo 1 shows the carved hammer. It was a rough attempt but close enough to try again.
Photo 2 is an array of the basic parts before assembly.
Photo 3 is the counter weight assembly.
Photo 4 is the router mounted in its swivel housing.
Photo 5 is the stylus holder and friction lock to lock out the swivel function when I don’t want it.
Photo 6 is the completed copy carver assembly. I added the piece of plywood above the handle after I carved the hammer because I was getting some twisting action between the stylus and the router when carving.

Here is my “photobucket” link http://s1263.photobucket.com/albums/ii625/luv2learn3/Copy%20Carver/ with more detailed photos and descriptions for those of you who are interested. I am sure that this design will get tweaked further since I just can’t let well enough alone. Thanks for looking!!

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green





16 comments so far

View Jim Jakosh's profile

Jim Jakosh

11099 posts in 1710 days


#1 posted 792 days ago

Very nice duplicator. It looks like it does a real good job!!..............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View woodshaver's profile (online now)

woodshaver

2739 posts in 1957 days


#2 posted 792 days ago

You have more energy than that bunny!!! They should put you on the Cool Tool show!
What’s your next project luv2learn?

-- Tony C , My high school shop teacher said "You can do it"... Now I can't stop!

View Rick's profile

Rick

6455 posts in 1637 days


#3 posted 792 days ago

Very Nice Indeed!

-- COMMON SENSE Is Like Deodorant. The People Who need It Most, Never Use It.

View Gshepherd's profile

Gshepherd

1437 posts in 806 days


#4 posted 792 days ago

I need one of these….. Nice Job…...

-- What we do in life will Echo through Eternity........

View HalDougherty's profile

HalDougherty

1820 posts in 1841 days


#5 posted 792 days ago

Good looking carver. What are you going to duplicate with it? Here’s a link to the patent documents for the Don Allen duplicator I use to carve gunstocks. If you build version 3, this link could give you some additional ideas. I can also take detailed photos of my duplicator for anything that’s not clear in the patent documents.

http://www.google.com/patents/about?id=xw48AAAAEBAJ&dq=don+allen

Here’s a detailed photo showing details of the parallelogram working frame. The router moves vertically and doesn’t move in an arc so you can drill very accurate holes at any angle. I did a quick google search to find a picture of the headrig.

-- Hal, Tennessee http://www.first285.com

View Roger's profile

Roger

14177 posts in 1408 days


#6 posted 792 days ago

Super engineering feat! Wow

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View Mauricio's profile

Mauricio

6752 posts in 1756 days


#7 posted 792 days ago

That is too cool, the possibilities are endless with what you could do with that thing!

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

View helluvawreck's profile

helluvawreck

15452 posts in 1471 days


#8 posted 792 days ago

Nice work on this duplicator, luv2learn. I’m going to favorite this so I can refer to those patent drawings. Thanks for those, Hal.

helluvawreck
https://woodworkingexpo.wordpress.com

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View luv2learn's profile

luv2learn

1646 posts in 907 days


#9 posted 792 days ago

Thanks everyone for all the kind words. Thanks Hall for the patent link, I checked it out. That is one serious duplicator and for guys like yourself who do some serious carving that is the ticket. There is nothing like having the right tool for the right job :).

I guess the challenge for me is to take a concept like the copy carver and try to build a functioning one on the cheap. I might have $30.00 dollars invested in this project. Now, if I really get interested in doing some serious copy carving I will break out the cutting torch, welding machine, and cut off saw and build one out of metal but then I couldn’t post it on LJs :).

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View Michael Wilson's profile

Michael Wilson

587 posts in 1095 days


#10 posted 792 days ago

Oh yeah. This is on the short list.

View HalDougherty's profile

HalDougherty

1820 posts in 1841 days


#11 posted 791 days ago

Luv2learn,

There’s no reason you couldn’t build a duplicate out of birch plywood. As long as you use some good bearings to take the slop out of the linkages, you should be able to build a prototype that works just like mine does. Then if you use it enough, replace the parts, a few at a time with 1/2” structural aluminum or steel. One reason my duplicator is accurate is the weight of the machine. The headrig weighs over 300 lbs, but the router and the mount holding the stylus are balanced by a tank full of bird shot, so the rig slides by just a tiny bit of pressure. It takes almost no effort to move it in any direction.
If you make a duplicator out of steel or aluminum, post a project you’ve made with it, and feature it in the background! I’m sure it would make the days top 3.

-- Hal, Tennessee http://www.first285.com

View luv2learn's profile

luv2learn

1646 posts in 907 days


#12 posted 791 days ago

Hal, you give good advise. Let me share this link you gave me with the other LJs.

For those of you that are thinking about building your own copy carver check out Terrco This would be a simple copy carver design to use as a model for your own build.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View HalDougherty's profile

HalDougherty

1820 posts in 1841 days


#13 posted 791 days ago

View totalrewind's profile

totalrewind

15 posts in 876 days


#14 posted 788 days ago

Why does it have to be 1-to-1? Could you just use a bigger stylus to enlarge the object (or versa-visa)?

View luv2learn's profile

luv2learn

1646 posts in 907 days


#15 posted 787 days ago

Totalrewind, yes you could use a larger stylus and a small router bit to increase the size of your pattern some and visa versa. You have some flexibility depending on the pattern design.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

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