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  1. #31
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    So I made friends with the maker linked in the first post .
    Told him about who I hang about with online and the trouble this can lead to and asked him how he made his legs .
    And asked what sizes they were.

    His answer.

    Roughed out on a panel saw then rounded on a router table . Not rotated over the cutter but shaped with radiused bits . He gets custom bits made . And the Leg sizes are from 25 to 60mm diameter.

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  3. #32
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    That’s exaclty how I made mine for my footstool

    4A3AEAB5-D329-47B3-903F-E49F56117FCD.jpeg
    Last edited by Lappa; 22nd March 2019 at 10:00 AM. Reason: Photo added

  4. #33
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    Why wouldn't you just spin em up on a lathe? Auto lathe if there were heaps to do, or am I missing something?

  5. #34
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    Find a tame turner . . .

    For me, if it's to be round and under 950mm in length, then it goes on the Yellow Peril.

    The idea of doing this on a Spindle Moulder is feasible, but not in my skill set. My moulder is used for basic machining, as that is my skill level with that machine.
    I very well respect it, it's a wide awake machine. You either use it wide awake or it will awaken you very blessedly quickly!
    Pat
    Work is a necessary evil to be avoided. Mark Twain

  6. #35
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    Quote Originally Posted by rustynail View Post
    Why wouldn't you just spin em up on a lathe? Auto lathe if there were heaps to do, or am I missing something?
    You would , and I would for a one off if the next machine I had above the basic machines in a workshop was a lathe.

    And the link shows the maker does a range of diameters and goes through quite a few legs .

    But we were answering the question of how a pro would do it .

    There are plenty of ways a pro would do it . The copying machine I showed that does one at a time is fast .Though the same thing on cnc with auto feed would be super fast and cleaner finish.
    My machine is as old as the hills. The same method was used on machine that I saw that had one template and three machine heads cutting wood that I saw at Hutchins wood machinists in Collingwood. One pass and three legs are done. They had two or three of these copiers lined up.

    Then I saw one in a video that did twelve I think ? At a a time off one template . Doing WW2 Gunstocks . One run twelve gunstocks. With a line of the same machine running at the same time from bad memory.


    Rob

  7. #36
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    Quote Originally Posted by auscab View Post
    You would , and I would for a one off if the next machine I had above the basic machines in a workshop was a lathe.

    And the link shows the maker does a range of diameters and goes through quite a few legs .

    But we were answering the question of how a pro would do it .

    There are plenty of ways a pro would do it . The copying machine I showed that does one at a time is fast .Though the same thing on cnc with auto feed would be super fast and cleaner finish.
    My machine is as old as the hills. The same method was used on machine that I saw that had one template and three machine heads cutting wood that I saw at Hutchins wood machinists in Collingwood. One pass and three legs are done. They had two or three of these copiers lined up.

    Then I saw one in a video that did twelve I think ? At a a time off one template . Doing WW2 Gunstocks . One run twelve gunstocks. With a line of the same machine running at the same time from bad memory.


    Rob
    Rob

    I have seen tool handles made much the same way. Four timber blanks oscillating back and forward following a steel axe pattern is impressive.

    Regards
    Paul
    Bushmiller;

    "Power tends to corrupt. Absolute power corrupts, absolutely!"

  8. #37
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    Making a 60mm dowel on a router table seems really complicated. What do you guys think the cutter looks like? Like a half round?

  9. #38
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    Quote Originally Posted by Bushmiller View Post
    Rob

    I have seen tool handles made much the same way. Four timber blanks oscillating back and forward following a steel axe pattern is impressive.

    Regards
    Paul
    Yeah Paul . The Machines in Collingwood I saw Had Brass template and the three timber cabriole legs that were being cut were machined laying horizontal but one above the other like the rungs of a ladder . They are a well known machine I think amongst those machinist type guys . Ive forgotten the name of them but a guy who did know knew where those machines went when Hutchins shut down .

    The Goldie I have came with Axe handle cast iron templates . Three I think . Just an axe handle in cast iron . The machine also came with Oar head templates in cast iron which is what it was set for cutting before I converted it to a furniture parts machine . Which was just putting a tail stock in place of where the oar holding device was fitted.

    I found the WW2 video I saw a few years back copying Walnut Gun stocks. Possibly for the Lee Enfield?
    Jack Forsberg shared it a few years back on Canadian Forum and someone mentioned Lee Enfield there.

    The stock in two parts looks to be shaped in two machines . One doing 8 at a time and another doing 4 at a time . That part is at the 14.30 mark .

    https://movingimage.nls.uk/film.cfm?...arch_fuzzy=yes


    Rob

  10. #39
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    Quote Originally Posted by qwertyu View Post
    Making a 60mm dowel on a router table seems really complicated. What do you guys think the cutter looks like? Like a half round?
    I would think taking 4 x 45 degree cuts off the square blank to get it down close would be the panel saw part. There would still be enough left to keep the wood tracking straight off the router fence.
    Then a 4 x pass with a quarter round bit . A 30 mm radius bit is nothing to scary on a decent router.

    Featherboards are great but I don't see one working on something that was square to start with and then is becoming round. Unless they press in the middle .They as in one from the side and one from the top. You would have to leave the tiniest flat for it to work maybe?

    I was thinking of how improbable and big a half round cutter would be for the spindle moulder earlier in this thread for a 65 to 70mm leg. 4 passes and a skim cut and a router table does it !

    The guy also said he cut the mortises while the piece was still square.

    Rob

  11. #40
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    An auto lathe with auto feed would run rings around a spindle moulder . You did stipulate how the pro's would do it. Some of the notions put up here are way under pro class. Anything requiring multi feed becomes pretty amateurish.

  12. #41
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    Professionals do lots of things depending on their main line of work, a one off commision is different to a repeated design which is different to production line!

    Batching saves a lot of money and time, the higher production methods have higher setup and capital cost.

    In a single morning my uneducated complete guesses, including setup, from square stock to ready for sanding:
    Hand planes and scrapers 5m
    Manual lathe 50m
    Router table 1/4 round bit 100m
    Spindle moulder half round bit 200m
    Auto lathe 300m
    One pass 4 side moulder 1000m
    Custom continuous factory line 5000m

    And as always, any time anyone mentions a spindle moulder or electrical wiring someone completely loses their mind!

  13. #42
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    Quote Originally Posted by rustynail View Post
    An auto lathe with auto feed would run rings around a spindle moulder . You did stipulate how the pro's would do it. Some of the notions put up here are way under pro class. Anything requiring multi feed becomes pretty amateurish.
    Yeah, we used to use an auto lathe for lengths under 1500mm (2-3mins each and they come off lathe sanded to 150grit). Long lengths for retirement home handrails went through the four sided moulder, not sanded but cleanly cut.

  14. #43
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    Quote Originally Posted by Kuffy View Post
    Yeah, we used to use an auto lathe for lengths under 1500mm (2-3mins each and they come off lathe sanded to 150grit). Long lengths for retirement home handrails went through the four sided moulder, not sanded but cleanly cut.
    Two to three minutes each! What, was it horse drawn? I have a mate with a fully auto lathe and when we fill it for stair spindles, it chucks one out every 30 seconds! I love the thing. Nothing more boring than standing in front of a manual lathe turning out the same thing all day. It's like having a bloody office job.

  15. #44
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    Running long'ish spindles was only small run work. The same machine would turn and sand a 300mm long coffin handle in 22secs (slower than rotary knife but less skill level required and it was our only fully automatic machine). If the planets aligned I could get it down to about 18secs if I recall correctly, but you had to watch it pretty closely while doing other things to make sure the linishing belt is still doing a "good enough" job. Coffin handles were big run jobs of 2000 or more pieces. So a second in time saving worked out nicely. But when running 10 pieces, I really couldn't care less if it took an extra 10minutes. Beats setting up a rotary knife lathe to spit them out or setting up the moulder for what would quite literally be a 1 minute production run time

  16. #45
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    I make these all the time for a client. In both pine and ash.

    They are done on a router table with a bullnose bit, in four passes, if less than 20 mm... And for larger ones I do on the lathe.

    I just use calipers and a skew. Very quick and super extra accurate.

    If you want a manual way of doing it with a plane, use this technique: https://www.instagram.com/aklein2303/p/BvWPYPtHjjC/ ... Obviously one needs a few more passes than this hexagonal, but it's very quick. Just make a long enough jig.

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