Home made duplicator overview
 

I don't claim that anything I show in this thread is particularly original but there may be some things in the pictures that will give newbies something to think about.

I made a duplicator using a 1940's Sears wood lathe and a Ryobi laminate trimmer. Here's an overview shot of my setup.

Router section
 

http://www.ukuleles.com/Jigging/DuplicatorRouter.jpg

http://www.ukuleles.com/Jigging/DuplicatorRouter2.jpg

The Ryobi laminate trimmer is held onto a little "sled" with stainless hose clamp. There is a bolt screwed into the bottom front of the sled that is the same diameter and end shape as the bullet nosed router bit. The end of the bolt and the tip of the router bit must be horizontally and vertically aligned to one another for consistent results.

Nice looking set up, well designed. I think my lathe is older, but not as old as Numbskulls.

Vacuum system
 

A Shop Vac is attached to the back of the support board which in turn holds a metal sheet. There is ~1 inch clearance between the bottom of the sheet and the template floor which allows the chips to run into the metal enclosure and then into the vacuum.

http://www.ukuleles.com/Jigging/DuplicatorVacuum.jpg

Template system
 

A wooden plate that is T-shaped in cross section drops into the bed space between the lathe runners and is held in place horizontally by the right hand base of the end-piece on the lathe.

The templates are made of composite flooring material left over from a previous honey-do. They're held in place with two screws that go into inserts in the wooden plate. Changing template shape is easy with a file or sander.

http://www.ukuleles.com/Jigging/DuplicatorTemplate.jpg

Ready 2 Go
 

A towel on the right provides additional blockage of openings for vacuum efficiency and a hinged polycarbonate shield safety during the turning process.

http://www.ukuleles.com/Jigging/DuplicatorReady2Go.jpg

The router must be held firmly during the turning process and small bites taken. All in all a fairly simple setup and made from materials on hand.

Nice setup Dave!

Lets see some pics of some curly Koa on that!!!