| Lathe pattern copiers are expensive and are not | | | | saw blade. With the blocks standing on edge, drill |
| available for many wood lathes. Pattern copiers are | | | | completely through each block between the hole and |
| used to make duplicate turned spindles from an original. | | | | the end of the block. Use a drill diameter slightly larger |
| Here's how to make your own. | | | | that the shaft diameter of the 10-40 bolts. Insert one 1 |
| You will need a piece of 1/2 aluminum tubing as long | | | | ½" 10-40 bolt through the hole you just drilled and |
| as your lathe bed or a bit longer to make your lathe | | | | place a wing nut and washer on the end. The idea is |
| pattern copier. You will also need some 1/8" thick | | | | that the wooden blocks will slip onto the pipe and the |
| aluminum sheeting or you can buy some aluminum | | | | bolts and wing nuts will hold them in place by closing up |
| cookie sheets. Purchase a box of 10-40 bolts 1 1/2" | | | | the 1/8" cut you made on the table saw. |
| long and a wing nut and washer for every bolt. Buy a | | | | Drill another bolt hole of the same diameter about 1/2" |
| second box of 10-40 bolts 1" long with nylon-lined lock | | | | from the other end of the block, centered with the |
| nuts for every bolt. You will need (4) 3" angle irons with | | | | block laying flat on the drill press table. Cut another 1/8" |
| screws, as well. The rest of the parts for your lathe | | | | slot, 1" deep and centered through the 1¼" dimension, |
| pattern copier can be made out of any scrap wood | | | | at right angle to the bolt hole. Remove one end of the |
| you may have laying around the shop. | | | | pipe from the vertical support posts. You can now |
| The design of this lathe pattern copier incorporates | | | | mount the blocks along the pipe before replacing the |
| multiple feeler "fingers" suspended behind the lathe | | | | pipe in the vertical support post of your lathe pattern |
| along the aluminum pipe. These fingers are adjusted to | | | | copier. |
| match the exact depth of the cuts in your original | | | | Cut aluminum fingers out of the flat stock using a 1/4" |
| turned spindle. When you place a new spindle blank on | | | | blade on the band saw. The fingers should measure 6" |
| the lathe, all of the lathe pattern copier fingers you | | | | long and 3/4" wide. Both ends should be completely |
| adjusted will be laying on top of the blank. As you cut | | | | rounded (3/8" radius) on an edge, belt or disc sander. |
| into the blank, prepare yourself to stop cutting as soon | | | | Drill a 10-40 bolt hole in one end of each finger |
| as the fingers relating to that cut drop down and | | | | centered 1/2" from the end. Sand the fingers smooth, |
| through the cut. | | | | removing saw marks and burrs. |
| Make two, vertical support posts about 6" higher than | | | | Mount the aluminum fingers onto the ends of the |
| the top of the largest spindle blank you can turn on | | | | wooden blocks, securing them in place with the 1" |
| that lathe. Note the outside diameter of the aluminum | | | | 10-40 bolts and lock nuts. The aluminum fingers must |
| pipe and drill a hole of that size near the top of each | | | | be free to move up and down. |
| support post. Mount the posts using the angle irons on | | | | Now place your original spindle on the lathe. Set the |
| the lathe table immediately behind the lathe. Insert the | | | | fingers to just drop through, barely touching the depth |
| pipe through both holes to make sure it fits.This will help | | | | of each cut. Place the first blank on the lathe with the |
| position the aluminum fingers of your lathe pattern | | | | fingers you just adjusted resting on top of the spinning |
| copier so that they can reach the spindle you are | | | | blank. Start cutting and stop as each finger falls |
| turning. | | | | through. |
| Make a bunch of wood blocks 3/4" x 1¼" x 6" long. | | | | Bob Gillespie |
| Drill a pipe sized hole in one end of each of them | | | | Woodworker |
| through the ¾" thickness. With the blocks lying flat, | | | | ©2010 Robert M. Gillespie, Jr. |
| cut through from the end into the hole with a 1/8" table | | | | |
