Router Duplicator

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As a kind of woodworking Xerox machine, this device helps you duplicate shallow carvings and curved moldings, hollowed chair seats, and even signs. And it does all this while floating on a thin cushion of air.

The most arresting thing about this device is not how gawky it is. It isn't the mystery of WHAT, exactly, it

IS. What stops you in your tracks is this: It's a hovercraft! It's a fantastical woodshop hovercraft! It isn't on wheels or casters. It isn't sliding on a smooth, slick surface. It is literally FLOATING ON AIR!

Of course, once you get your brain restarted, you DO want to know just what this ungainly device is. The answer is: It is a shop-built router duplicator. If you have a three-dimensional object, for example, a shallow carving or a sign, you can make a copy with this device.

The duplicator consists of two horizontal beams and two vertical columns, all joined to an air-flotation platen. The upper beam has a stylus mounted at its front end. A lightweight laminate trimmer is mounted in the corresponding position on the lower beam. A central column, rising from the platen and joined to the beams through ball-bearing pivots, supports both beams. A second column, attached with pivots to the ends of the two beams, keeps them parallel as they tilt up and down.The platen allows the device to be moved to and fro over a smooth, flat surface.

Once the duplicator, the original (or pattern), and the working stock are set up. duplicating is a matter of tracing over every inch of the original's surface with the stylus. As you do this, the router's bit is carving out a duplicate.

This is possible because the device holds the stylus at a fixed distance directly over the bit. (The distance is slightly adjustable during setup; but once setup is completed, the distance is fixed.) The stylus and bit can rise and fall, but thev do so together and they always share the same axis. That's the magic of the pivoting beam-and-column design. The platen allows the duplicator to swing side to side and to advance and retreat on its cushion of air, but the beam-and-column structure maintains the stylus-bit axis.

While the dynamic of the superstructure is quickly cvi-

conlimted

Router Surface Plane

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ROUTER DUPLICATOR PLAN VIEWS

TOP VIEW

SIDE VIEW

-J24

BOTTOM VIEW

Cutting List

Part

Qty.

Dimensions

Material

Pivot blocks

A

YS x 2" X 4'/i"

Hardwood

Beam sides

A

x 25^" x 48H

Hardwood

Beam webs

8

!4"x5H"x 19H-

Plywood

Column sides

6*

y*m x 2" x 12"

Hardwood

Platen-mount column sides

3*

fc" x 2" x 4"

Hardwood

Platen

1

fc" x 1 5" x 20"

Plywood

Platen surface

1

1^6" x 16" x 2 r

Plastic laminate

Attachment block

1

fc" x 1 x 2"

Hardwood

Mounting bar

H" x 1 VC x 5 H"

Plywood

ROUTER DUPLICATOR PLAN VIEWS-CONTINUED

Carving Wooden Duplicator

Hardware

8 ball bearings, x/¿" bore x 1 %" O.D. x W long 8 O-rings, i*" dia. drywall screws. #6x1" I T-nut, M*"-I8

I threaded rod, *6"-18 x 1414"

I threaded rod, x 18"

I steel bar, W x V x 5 W I bolt, día. to match router bit, 3" long 1 wing nut. size to match bolt OR 2 hex nuts, size to match

Router Duplicator Plans
x 30" as described In the text.

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Wood Working for Amateur Craftsman

Wood Working for Amateur Craftsman

THIS book is one of the series of Handbooks on industrial subjects being published by the Popular Mechanics Company. Like Popular Mechanics Magazine, and like the other books in this series, it is written so you can understand it. The purpose of Popular Mechanics Handbooks is to supply a growing demand for high-class, up-to-date and accurate text-books, suitable for home study as well as for class use, on all mechanical subjects. The textand illustrations, in each instance, have been prepared expressly for this series by well known experts, and revised by the editor of Popular Mechanics.

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