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-   -   Shaping machine, aka Copy Carver (http://www.wakeworld.com/forum/showthread.php?t=641564)

surfdad 11-01-2008 8:11 PM

I purchased the plans to build a Copy Carver, which is a router pantograph. Then I blew it up to a 4' x 8' size. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/641565.jpg" alt="Upload">

surfdad 11-01-2008 8:14 PM

The stylus on the left follows the shape of the board and transfers that to the router which duplicates the board into the foam. <BR> <BR>Mid cut, and my shop vac attempting to gather the cut EPS. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/641568.jpg" alt="Upload"> <BR> <BR>(Message edited by surfdad on November 01, 2008)

surfdad 11-01-2008 8:20 PM

I didn't have a big enough piece of foam, so I just played with my new "toy" to see how it worked and learned a few things. I was using a small section of pencil as my stylus and it broke! When the stylus breaks the router digs into the foam. A metal stylus is the only option. <BR> <BR>I got tired and started pushing the router side of the pantograph and that dug into the foam, you simply must go slow and adjust/push from the stylus side. <BR> <BR>A gouge and the indent as I was pushing the router side. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/641574.jpg" alt="Upload">

surfdad 11-01-2008 8:22 PM

The concave was matched perfectly, as was the rocker. It's an exact duplicate. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/641578.jpg" alt="Upload">

notsobueno 11-01-2008 8:22 PM

That is SO COOL. Can I come play? <img src="http://www.wakeworld.com/MB/Discus/clipart/proud.gif" border=0>

surfdad 11-01-2008 8:24 PM

Absolutely! Bring foam! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0>

ragboy 11-01-2008 10:19 PM

that is pretty cool.

ds3 11-02-2008 1:01 AM

That is tricky... cool.

bigshow 11-02-2008 7:20 AM

Ya, bring foam, a dust mask, a spare shop vac, and a broom. <BR> <BR>Surf Dad never stops!

hatepain 11-02-2008 11:57 AM

Sweet! Now we can have knock offs made in the USA! LOL<img src="http://www.wakeworld.com/MB/Discus/clipart/rofl.gif" border=0>

smedman 11-02-2008 5:05 PM

Nice Jeff! <BR> <BR>The poor man's CNC!! Excellent!

surfdad 11-02-2008 6:45 PM

Thanks Guys...Hate N, we could knock off the knock offs! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> Some cool trade name like KO squared. <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> <BR> <BR>Smed it's true! I've been making the same basic shape for a few years now and I've found that if I could get one within 1 mm of the master it was GREAT! This would be a great tool for a small shop that can't afford the $60K for a machine, and that wants to crank out a bunch of stock shapes.

hatepain 11-02-2008 7:40 PM

KO Squared "knocking off the best knock offs of the best boards since 2008"

surfdad 11-03-2008 4:39 AM


konaking 11-03-2008 5:50 PM

By George you have done it again SD

hawaj 11-03-2008 9:47 PM

what the heck thats awesome <img src="http://www.wakeworld.com/MB/Discus/clipart/rofl.gif" border=0> <BR> <BR>NASA = National Agency of Surfdad's Appliances <BR> <BR>Jeff you should buy bigger bits sou you can eat more foam at once <BR><a href="http://www.shapers.com.au/images/machine.cutter.jpg" target="_blank">http://www.shapers.com.au/images/machine.cutter.jpg</a> <BR> <BR><a href="http://www.shapers.com.au/category18_1.htm" target="_blank">http://www.shapers.com.au/category18_1.htm</a> <BR> <BR>not cheap

hawaj 11-03-2008 9:51 PM

and Jeff you need some counter balance springs so you don't plunge in the foam when you asleep at the router, he he <img src="http://www.wakeworld.com/MB/Discus/clipart/biggrin.gif" border=0>

hawaj 11-03-2008 10:10 PM

homemade CNC <BR><a href="http://smorel.net/page_cnc_fv3.php" target="_blank">http://smorel.net/page_cnc_fv3.php</a> <BR> <BR><a href="http://smorel.net/page_cnc_fc.php" target="_blank">http://smorel.net/page_cnc_fc.php</a> <BR> <BR>but its worth to buy some complete system then mess with all that machinery, electronic, computing and programing I guess <img src="http://www.wakeworld.com/MB/Discus/clipart/uhoh.gif" border=0> <BR> <BR>or simply just scan original at CNC shapers shop and let them route copies with modofications which you change on your PC. I guess its not so expensive. Its quick, clean and very exact. <BR> <BR>(Message edited by hawaj on November 03, 2008)

hawaj 11-03-2008 10:23 PM

check out <a href="http://www.aps3000.com/" target="_blank">http://www.aps3000.com/</a> system with free software

hawaj 11-03-2008 10:25 PM

can I copy my girlfriend? <img src="http://www.wakeworld.com/MB/Discus/clipart/lol.gif" border=0>

surfdad 11-04-2008 4:59 AM

$395 for a cutter! That's almost three times what I have into this stupid thing! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> The one issue with this device is that the stylus has to duplicate the cutter/bit otherwise the cut into the foam will be off. <BR> <BR>The Copy Carver does have a counter balace, but it's weights, still when the stylus breaks - that EPS will get a gouge. Hopefully I won't fall asleep at the wheel! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> <BR> <BR>Those CNC, even the DIY versions, are so expensive. I've priced them in kit form and it's several THOUSAND (close to 8K if I remember) to get one with x, y and z axis in the 2' x 5' x 4" range. <BR> <BR>I'm thinking the lady you are which to copy WON'T be your girlfriend after a session on the copy carver!!!!! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> <BR> <BR>The stylus/cutter combo I am waiting on. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/642123.jpg" alt="Upload">

smedman 11-04-2008 11:49 AM

Jeff - I was going to ask you if you were going to get a shaping burr and stylus like that. were you able to score them for a decent price?

surfdad 11-04-2008 12:20 PM

Not bad - $35 for the set. Saburr Tooth bits are available locally for cheap, but it's the matching stylus that is the pricey part. <BR> <BR>CC has <a href="http://www.copycarver.com/copy_carver_burrs.htm" target="_blank">these</a>

surfdad 11-04-2008 12:41 PM

I meant to post the pictures from last night. I did a little more testing. If the master has the fin box cuts in it, you can duplicate that on the cut piece. I even tried the C-5 holes and the machine handled that. It will require a bit/stylus change, no doubt. Straight plunge for the fin boxes and outline and then the bullnose for the curves.

konaking 11-05-2008 4:28 AM

Off the Hook SD. Whats cooking in the lab now<img src="http://www.wakeworld.com/MB/Discus/clipart/biggrin.gif" border=0>

surfdad 11-05-2008 5:51 AM

Thanks Bob, <BR> <BR>HD skins and e.Balsa rails is my next project, IF and that is a BIG IF, I ever finish the paint on the current project! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0>

surfdad 11-06-2008 5:25 AM

In progress, is this blank. I don't know what I did with the cutting pictures, I must have deleted them...anyway, the concave and rocker cut from the master. However, on this build I want to use e.balsa rails, so I cut the outline about 1/2" inside the final outline (blended at the tail and nose). <BR> <BR>I made plywood patterns that will allow me to cut the blank for the perimeter stringers. One is inset about 1.5" and this last one is about .5" inset. Then I attach the patterns to the cutting machine in place of the master and run the stylus just around the OUTSIDE of that pattern and it cuts the blanks outline leaving a vertical edge for attaching the stringers or in this case the rails. <BR> <BR>I did get pictures of the blank as I am sealing the bottom prior to attaching the bottom skin, and the vertical cut ready for the e.balsa attachment. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/642722.jpg" alt="Upload"> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/642723.jpg" alt="Upload">

surfdad 11-08-2008 6:45 PM

Some cut photos and the results <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> Do not give me crap about the last photo where I am sealing the blank, it started to RAIN right after I got started, so...it's a quick photo then I yanked it indoors. <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/643308.jpg" alt="Upload"> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/643309.jpg" alt="Upload"> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/643310.jpg" alt="Upload">

surfdad 11-08-2008 6:49 PM

Some of the OTHER results. <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/643319.jpg" alt="Upload"> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/643320.jpg" alt="Upload">

sinkoumn 11-08-2008 9:08 PM

Now THAT'S a good dog!

konaking 11-09-2008 6:29 AM

Love the dog shot SD <img src="http://www.wakeworld.com/MB/Discus/clipart/rofl.gif" border=0>

hawaj 11-09-2008 10:54 AM

Surfdad knows best <img src="http://www.wakeworld.com/MB/Discus/clipart/biggrin.gif" border=0>

hawaj 11-09-2008 10:55 AM

Jeff put some kind of tent around your rig

surfdad 11-10-2008 5:08 AM

I need to move it outside, Petr! <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> Isn't Woofie the best dog ever? <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0> He follows me everywhere in hopes of getting attention or a snack. <IMG SRC="http://www.wakeworld.com/MB/Discus/clipart/happy.gif" ALT=":-)" BORDER=0>

hawaj 11-10-2008 6:08 PM

and then he got only tons of foam <img src="http://www.wakeworld.com/MB/Discus/clipart/biggrin.gif" border=0> wooof

surfdad 11-15-2008 5:57 AM

I decided to do this blank in carbon. <BR> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/644795.jpg" alt="Upload"> <BR><img src="http://www.wakeworld.com/MB/Discus/messages/559019/644796.jpg" alt="Upload">

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