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copy carver/duplicator 2.0

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Project by luv2learn posted 05-30-2012 01:21 AM 13810 views 24 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

11550 posts in 1771 days


#1 posted 05-30-2012 02:50 AM

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

woodshaver

2778 posts in 2019 days


#2 posted 05-30-2012 02:55 AM

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

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

View Rick's profile

Rick

6454 posts in 1699 days


#3 posted 05-30-2012 09:02 AM

Very Nice Indeed!

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

View Gshepherd's profile

Gshepherd

1472 posts in 867 days


#4 posted 05-30-2012 09:12 AM

I need one of these….. Nice Job…...

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

View HalDougherty's profile

HalDougherty

1820 posts in 1903 days


#5 posted 05-30-2012 10:33 AM

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

14649 posts in 1470 days


#6 posted 05-30-2012 11:57 AM

Super engineering feat! Wow

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

View Mauricio's profile

Mauricio

6820 posts in 1817 days


#7 posted 05-30-2012 01:23 PM

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

15893 posts in 1532 days


#8 posted 05-30-2012 03:26 PM

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

1715 posts in 969 days


#9 posted 05-30-2012 04:09 PM

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 1156 days


#10 posted 05-30-2012 05:16 PM

Oh yeah. This is on the short list.

View HalDougherty's profile

HalDougherty

1820 posts in 1903 days


#11 posted 05-30-2012 05:50 PM

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

1715 posts in 969 days


#12 posted 05-30-2012 08:37 PM

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 1903 days


#13 posted 05-30-2012 08:49 PM

View totalrewind's profile

totalrewind

15 posts in 938 days


#14 posted 06-03-2012 05:14 PM

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

1715 posts in 969 days


#15 posted 06-03-2012 08:08 PM

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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