After finding an article by Jim Wilson –http://www.paragoncode.com/shop/duplicator/ I was inspired to build a duplicator for my Shopsmith.
The idea of a simple duplicator came to mind aftter seeing a set of European wooden nativity scene figures that were made entirely from turned shapes. I thought this simple duplicator would be perfect to produce several sets.
With the Shopsmith I am able to mill and cut aluminium so the tool carrier was made from a billet of 1/2′ material 7 1/2″ x 4″ alloy which was mounted to the base made from 4″ x 4″ x 1/4 alloy angle with 3- 1/4″ UNC machine screws. Since I had 5/16″ sq x 4″ HSS tool stock I used this and cut a slat .300″ deep to locate the tool bar.
The template follower was made by drilling a #10-32 bolt to accept an expired metal ball point.
 |
| Thimble Template |
 |
| Template Follower |
 |
| Setting datum point to material |
To try out the set up a compiled the best features several sewing or mending kit designs and made templates for from 1/8″ thick sheet acrylic. I was quite pleased with the results. However, further refinement is required as I used an offcut of countertop for the table but discovered that it was not true flat causing some tool wobble/chatter so I will remake that part using 2 layers of 3/4″ cabinet grade ply.
 |
| 7 wooden men |
 |
| Detail view 4 components |