Uze guys just keep me learnin.:kewl: :hihi:

Today I had a few minutes at break so I ground a roundnose bit like capesams showed and put it in the tool post. It cut a lot better than what I was using. I still had to sand a bit, but pretty much no tearout this time. I have to wait until the weekend to set the duplicator back up 'cause it takes too long to set up and tear down for a half hour lunch break. Kinda sucks not having my own shop, but it has been a lot cheaper to use the tools at work than buying my own. I'll post the results for this when I can get to it. Thanks a bunch for all the help!

this thing is great!

Proffessor M, I sent you over a PM with a few questions. Not sure if went through. Just a few questions about the carbid bit.

PM sent

Additional ideas
 

Thought I would post in this thread because without professor's M's help this would have been a lot more difficult, as well as all the others that have shared their duplicators. Besides the insert, the insert holder, and the threaded rods everything was just scraps that I had at work.

Luckily enough the table saw top on the shop smith serves as decent adjustable platform minus the clearance being on little on the low side.

As others did, the bottom of the duplicator has plexiglas allowing it to slide on the platform easier. I'm sure lexon would be a lot easier to use as the plexiglass tends to crack a lot easier when cutting and drill but I just went slowly and it worked out.

I just happen to have a couple dock cleats from the marina laying around and I was brainstorming about some ideas for weight. looks a little silly but adds a some weight and also allow me to cup my hands in between the cleat and handle.

few additional photos.

more photos for more ideas.

templates - I sort of visualize everything on a computer because I spend more then 10 hours a day designing crap for work, so I drew out my templates directly on the computer. Although I'm sure at some point I will scan in plugs that I like and go from there as others did.
I also measure everything in decimals rather then fractions, just a work related thing.

Although it's not the nicest looking thing it works better then previous attempts. Professor M mentioned that I would most likely change the design several times before settling, and I assumed it shouldn't be problem the first time, I was wrong. I actually made an additional two along with these that I chucked away. I might have made a different one every day last week. :musc:

All in all, I hope this can also help someone out because without everyone's idea's I wouldn't have gotten this far.

excuse the spelling,grandma:as:, everything else that is wrong. I hate text editing

Good for you Frank I knew you could do it. Looks great. Great thinking and remedy for all the obstacles I am sure you encountered. I like it. Now wasn't that fun.

That came out pissa, I bet it works even better than most commercial ones. I like simple. Great job :btu:

thanks, Just worked around using crap that was laying around.
I work in huge storage garage at work, and with a little digging you can find all sort of things. I like making anything that contributes to what I'm trying to accomplish.

Paul-I still couldn't find those plastic star nut fasteners. Using the wing nuts for now. I will keep looking.

I will get you a few, we got some at work just sitting there. I will give to you at plugfest. 1/4 20 thread is that ok?

thanks professor!

1/4 will be fine. I'm using 5/16 threaded rod but it will a lot easier to use 1/4 as oppose to trying to find these fasteners.

I will no longer ask questions in a hardware store that isn't a mom and pop store. I was told twice "I've never seen anything like that" by two people who work in the hardware department while standing right near chop saws that have the same fasteners.

Now that I think of it I am not sure of the thread. Either 1/4 or 5/16. I will look and let you know.