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Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-01-2008, 8:11 PM Reply   
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.

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Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-01-2008, 8:14 PM Reply   
The stylus on the left follows the shape of the board and transfers that to the router which duplicates the board into the foam.

Mid cut, and my shop vac attempting to gather the cut EPS.

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(Message edited by surfdad on November 01, 2008)
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-01-2008, 8:20 PM Reply   
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.

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.

A gouge and the indent as I was pushing the router side.

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Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-01-2008, 8:22 PM Reply   
The concave was matched perfectly, as was the rocker. It's an exact duplicate.

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Old    dtw. (notsobueno)      Join Date: Dec 2004       11-01-2008, 8:22 PM Reply   
That is SO COOL. Can I come play?
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-01-2008, 8:24 PM Reply   
Absolutely! Bring foam! :-)
Old    Robert Garcia (ragboy)      Join Date: Aug 2007       11-01-2008, 10:19 PM Reply   
that is pretty cool.
Old    Derek (ds3)      Join Date: Jun 2008       11-02-2008, 1:01 AM Reply   
That is tricky... cool.
Old    Show (bigshow)      Join Date: Feb 2005       11-02-2008, 7:20 AM Reply   
Ya, bring foam, a dust mask, a spare shop vac, and a broom.

Surf Dad never stops!
Old    Hate N Pain (hatepain)      Join Date: Aug 2006       11-02-2008, 11:57 AM Reply   
Sweet! Now we can have knock offs made in the USA! LOL
Old    Smed (smedman)      Join Date: Feb 2006       11-02-2008, 5:05 PM Reply   
Nice Jeff!

The poor man's CNC!! Excellent!
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-02-2008, 6:45 PM Reply   
Thanks Guys...Hate N, we could knock off the knock offs! :-) Some cool trade name like KO squared. :-)

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.
Old    Hate N Pain (hatepain)      Join Date: Aug 2006       11-02-2008, 7:40 PM Reply   
KO Squared "knocking off the best knock offs of the best boards since 2008"
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-03-2008, 4:39 AM Reply   
LOLOLOLOLOLOLOL!
Old    Kona (konaking)      Join Date: Mar 2008       11-03-2008, 5:50 PM Reply   
By George you have done it again SD
Old    Petr (hawaj)      Join Date: Aug 2005       11-03-2008, 9:47 PM Reply   
what the heck thats awesome

NASA = National Agency of Surfdad's Appliances

Jeff you should buy bigger bits sou you can eat more foam at once
http://www.shapers.com.au/images/machine.cutter.jpg

http://www.shapers.com.au/category18_1.htm

not cheap
Old    Petr (hawaj)      Join Date: Aug 2005       11-03-2008, 9:51 PM Reply   
and Jeff you need some counter balance springs so you don't plunge in the foam when you asleep at the router, he he
Old    Petr (hawaj)      Join Date: Aug 2005       11-03-2008, 10:10 PM Reply   
homemade CNC
http://smorel.net/page_cnc_fv3.php

http://smorel.net/page_cnc_fc.php

but its worth to buy some complete system then mess with all that machinery, electronic, computing and programing I guess

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.

(Message edited by hawaj on November 03, 2008)
Old    Petr (hawaj)      Join Date: Aug 2005       11-03-2008, 10:23 PM Reply   
check out http://www.aps3000.com/ system with free software
Old    Petr (hawaj)      Join Date: Aug 2005       11-03-2008, 10:25 PM Reply   
can I copy my girlfriend?
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-04-2008, 4:59 AM Reply   
$395 for a cutter! That's almost three times what I have into this stupid thing! :-) 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.

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! :-)

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.

I'm thinking the lady you are which to copy WON'T be your girlfriend after a session on the copy carver!!!!! :-)

The stylus/cutter combo I am waiting on.

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Old    Smed (smedman)      Join Date: Feb 2006       11-04-2008, 11:49 AM Reply   
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?
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-04-2008, 12:20 PM Reply   
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.

CC has these
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-04-2008, 12:41 PM Reply   
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.
Old    Kona (konaking)      Join Date: Mar 2008       11-05-2008, 4:28 AM Reply   
Off the Hook SD. Whats cooking in the lab now
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-05-2008, 5:51 AM Reply   
Thanks Bob,

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! :-)
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-06-2008, 5:25 AM Reply   
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).

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.

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.

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Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-08-2008, 6:45 PM Reply   
Some cut photos and the results :-) 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. :-)

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Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-08-2008, 6:49 PM Reply   
Some of the OTHER results. :-)

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Old    Sinko (sinkoumn)      Join Date: Jan 2007       11-08-2008, 9:08 PM Reply   
Now THAT'S a good dog!
Old    Kona (konaking)      Join Date: Mar 2008       11-09-2008, 6:29 AM Reply   
Love the dog shot SD
Old    Petr (hawaj)      Join Date: Aug 2005       11-09-2008, 10:54 AM Reply   
Surfdad knows best
Old    Petr (hawaj)      Join Date: Aug 2005       11-09-2008, 10:55 AM Reply   
Jeff put some kind of tent around your rig
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-10-2008, 5:08 AM Reply   
I need to move it outside, Petr! :-) Isn't Woofie the best dog ever? :-) He follows me everywhere in hopes of getting attention or a snack. :-)
Old    Petr (hawaj)      Join Date: Aug 2005       11-10-2008, 6:08 PM Reply   
and then he got only tons of foam wooof
Old    Jeff Walker (surfdad)      Join Date: Sep 2004       11-15-2008, 5:57 AM Reply   
I decided to do this blank in carbon.

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