Duplicator

[ProfessorM]

Youngsalt to be honest with you I have not used any of the carbide tools yet. I have just used the high speed tool so far and it holds up well. You do have to stone the edge a little as it does get dull, but you can do a lot of plugs before it happens. I found wood like mahogany, cherry, rock maple to dull out the HSS tool quicker. I cannot see the carbide chipping unless you bang it up against something. It will probably wear a little on the cutting edge, thus it will need to be touched up periodicly, but should stand up to wood with no problem for a long time. The quality of the carbide also makes a difference too. I machine very hard stainless and they do eventually melt or chip but that is caused usually by me going to fast with the feed and rpm's or a coolant issue. I cannot see any wood we would use being hard enough to cause the tool to fail. I would definately make my own insert tool holder for your Vega. 80 bucks is highway robbery. You should be able to make a holder and then just buy an insert through your work to use in it. Then you do not need to sharpen them just index them in the holder or throw them out and use another insert. Got to be cheaper than 80 bucks. I just write on the template the name of the plug. Paul

[justplugit]

Hey Paul, pm'd ya.

[ProfessorM]

I have edited some of the text because I thought of a lot of stuff as I read back thru the process, just plain forgot. If you are going to build one you might want to reread the text. Good luck. Paul

[ProfessorM]

PM sent

[eskimo]

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.

[eskimo]

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.

[eskimo]

few additional photos.

[eskimo]

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.

[ProfessorM]

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.

[Slipknot]

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

[eskimo]

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.

[ProfessorM]

Originally Posted by eskimo

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?

[eskimo]

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.

[ProfessorM]

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.