Foot-powered lathe is a tour de force of joinery techniques

foot-powered-lathe

Meet [Quetico Chris]. He’s a master woodworker who likes to find his own alternatives to using power tools. Most recently, he was inspired by a fly-wheel from an old factory. He used it to build this foot powered wood lathe.

It works something like a foot powered sewing machine. There’s a lever for your foot which converts the downward force from your foot into a rotating force which drives the work piece. The mechanics of the lathe are pretty common, but we think the build techniques he uses are anything but. The video after the break shows each step [Chris] went through when crafting the human-power tool. His approach was to use wood as often as possible which includes foregoing modern fasteners for older joinery. He uses mortise and tenon, wood pinning, doweling, and a lot of puzzle-like tricks to get the job done.

We lack the skill and tools to replicate this kind of craftsmanship. We’re going to stick to letting a laser cutter form our wood connections.

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Recurve bow make from wood and skis

bow-made-from-ski

A little face protection is a great idea when first testing out your homemade bow. [Austin Karls] made this recurve bow during what he calls an engineer’s Spring break.

He settled on the idea after seeing a few other projects like it on Reddit. After first drawing up a plan he headed down to the shop to cut out the wooden riser (the middle part of a bow). Unlike traditional recurve bows this is made up of three parts. Traditionally you would laminate different types of wood to achieve the flexibility and tension levels desired. But [Austin] went with a synthetic material: the tips of two skis. Each were cut to the final length and affixed to the riser with a pair of bolts.

After a few test shots he gained confidence in the design and did away with the face mask. Now if you’re in the market to take your existing bow and add some firepower to it you’ll want to look in on this shotgun enhanced compound bow.

[Thanks Schuyler]

Wooden teeth for your USB keyboard

wooden-keyboard

We just got an ergonomic keyboard for the first time and absolutely love it. But the look of this keyboard hack has us second guessing ourselves. [Will Pretend] pulled off an absolutely stunning wooden retrofit for his USB keyboard. Be warned, his project log includes 175 photos, and most of them have captions.

He started off by taking apart the original USB keyboard to see what he was working with. Before digging in to the valuable wood stock he cut test pieces using some thin MDF. But once he had a clear plan to get to the end of the project it was full stem ahead.

The keys are not simple Chicklet style overlays, they have depth like you would expect to find on low-grade plastic peripherals. This was accomplished by milling each key, then sending them through the laser cutter to each the letter on top.

Take some time to make your way through the entire project (here’s a thumbnail layout if you get frustrated). Unfortunately [Will] says he doesn’t actually use the keyboard because of grains catching and the keys move around a bit too much. But it does work.

Wooden cargo bicycle

nearlycomplete

This is a cargo bicycle made almost completely out of wood. [Niels] and three of his classmates built it at Wico Campus Tio, a science and technology school in Dorpsstraat, Belgium. There’s a lot to be impressed by in this build. Sure, the guys concede that not everything is wood. They used metal screws as well as hubs, a crank shaft, and gears from a bicycle (not seen in this image). But everything else was made from Beech or Padouk wood. This includes the leaf springs that help cushion the cargo box from the bumps in the road.

The box itself acts as the handlebars. You can see the bracket which holds one end of a dowel spanning the left side of the box. This image was taken before the seat and cranks were added, but once they’re in place the front axle will turn along with the box for steering.

You can get a good look at the finished bike in the video after the break. You’ll also find a link to the Power Point slides there. Since that presentation is in Dutch we translated the text and pasted it below.

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Router jig for a perfect circle

router-jig-for-cutting-circles

We once enlisted a contractor to cut a plywood circle for a cat condo we were building. Now we’re embarrassed that we couldn’t come up with a solution as eloquent and easy to use as this circle cutting router jig which [Grays42] built.

He’s using a small trim router for the job. The jig is made up of two thick-walled pieces of PVC pipe. We don’t think the router is attached to jig. Instead you hold it against the wooden spacer which is on the outside edge of the cut. He doesn’t mention how he made the spacers, but we’d recommend cutting a hole the size of the pipes and then ripping down the middle to remove some of the material (tape the two spacers together during fabrication to ensure proper alignment). It just takes some nuts and bolts from the hardware store to assemble everything.

[Grays42] is using this to cut rings for his telescope build. We have our eye on it for making our own wooden Bulbdial clock.

[via Reddit]

Log coasters made with just two tools

diy-log-coaster-set

Still looking for that perfect gift? [Joel Witwer] shows us how to make a log coaster set and holder on the cheap. He figures he spent just $5 on the project and from what we can tell that all went to some polyurethane which he used to finish the wood pieces.

It started with an interesting-looking and appropriately sized log which he found on the side of the road. We’re not sure about the ins and outs of drying stock to ensure it won’t crack, but we hope he took that into account. With raw material in hand he headed over to the band saw. The cutting starts by squaring up both ends of the log while cutting it to the final length. He then cut the bottom off of the holder. What was left was set upright so that he could cut the core out of the log. This is the raw material from which each coaster is cut. A spindle sander was used to clean up all of the pieces. The last step before applying finish is to glue the bottom and sides of the holder back together.

[Joel] gave some tips in his Reddit thread. He says you should hold on tight while cutting out the slices for coasters because the round stock will want to spin. He also mentions that some of the slices aren’t as flat as they should have been, something to think about if you’re cutting these for yourself.

Building a mechanical counter out of scrap wood

Watching [Matthias Wandel] fabricate this mechanical counter from scrap wood is just fascinating. He likens the mechanism to the counters you would find on decades-old cassette tape players.

You may recognize the quality of [Matthias’] work. We’ve seen several pieces, but his binary adder is still one of our favorites. This project gives us a very clear view of the development and fabrication process. He even posted a detailed guide if you want to build your own.

He started by prototyping a mechanism to increment and decrement the counter. With that proven design he started laying out the rest of the gears. These were cut from plywood scraps he had from other projects. Notice the small gears seen above which are missing parts of some teeth. Those sections were removed using a drill press with a Forstner bit. The missing teeth cause the next digit over to increment more slowly, resulting in a 1/10 ratio. This part of the design is demonstrated about three minutes into the video after the break.

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