Robbie is safely enclosed!

Finished room!

Whew.  This project was a D-O-O-O-ZY!  We needed to enclose our giant industrial arm so he can’t run away and join the robot circus…

Well…maybe not for THAT reason, but when we start cutting stuff with this robot, we need to keep spectators out of his reach and make sure that if a cutting bit does break, it doesn’t go flying out into the shop and maim someone.

This entire project was the work of several people and really shows why the Milwaukee Makerspace is a great place to build stuff/hang out with friends/play with power tools, etc…

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Step 1: Design it!  I used Solidworks and modeled each and every piece of wood that went into this project.

SW screen capture

Step 2: get the wood!  We made multiple trips to Home Depot, which thankfully is only 5 minutes away and we had great weather during the whole building process.  I love having a truck!  Fortune also shined upon me, as we had a new member join up right before I started this project, Jake R., and his help in building the wall was immeasurable.

Get the wood!

Step 3: Bolt the wood to the floor so we know where to put the wall, and then build some framing!

  4 - put in windows

Step 4: Put in the windows, drywall paneling and metal wainscoting.  We were very lucky to get seven pieces of slightly-smoked Lexan from one of our members, Jason H.  We also cut small holes in the ceiling tiles and ran 4 braces up to the metal ceiling trusses above.  This enclosure is ROCK-solid stable!  Thanks to Tony W. and Jim R. for helping with that!

When I went to Home Depot, I thought my truck could handle a 48″x 120″ sheet of drywall.  Not so much… one of their employees helped me split 10 sheets of drywall in half, in the parking lot…so I would later find out that I did not have drywall tall enough for the wall corner.  Hence the need for more “framing” so I could use smaller pieces.

10 - outer framing

The large cabinet that powers the robot arm is right next to the enclosure; I placed it outside to keep it away from foam & wood shavings.  However, we will need to have the programming pendant next to the machine every now and then….hence the need for 2 small pass-thru doors next to the cabinet.

6 - hole for mini-door

11 - outer door installed

 

 

 

 

 

 

 

 

 

 

I used doweling to help hold the door frame components together…..probably not needed, but it ensures a STRONG door!

16 - drilling door frames  15 - door framing 1

Again, hooooray for the Makerspace and all its tools! We have several LONG pipe clamps that came in VERY handy for gluing the door frame pieces together.

17 - frame glued up - 1

Here’s the outside of the enclosure.  The big metal control cabinet will go right here, hence the framed “mouse hole” in the lower right corner so we can pass the cables through from the cabinet to the robot arm.

13 - outer door and mouse hole

The same area viewed from inside the enclosure.

14 - inner door and mouse hole

Here’s the ginormous sliding door.  It’s mounted on a barn-door track-rail and supported on the bottom by two custom-made wheel brackets.

23 - finished door on track

Here’s how I made the wheel brackets.  I got two lawnmower-style wheels and bearings from Tom G., then Tom K. enlarged the center holes on the wheels on his Bridgeport mill so I could use bearings for smoother action.

18 - wheels in slot - 1

I figured on four carriage bolts for a super-strong connection to the door frame.

19 - wheel assembly done

This is the track and wheel bogies that hold the sliding door to the wall.

22 - wheels and track

Bolting the brackets onto the door was “fun”…I forgot that the very bottom of the door framing is two horizontal pieces, so the very bottom bolt had to go.  ‘DOH!

21 - inside door frame 1

Here’s the final, assembled view.  You can see the robot’s control cabinet in the lower right corner.

Now that the fabrication is complete, we’re working on decorative ideas for all that blank-looking drywall.

24 - finished room!

Whenever I look at this finished project it feels like to took several months to get it up, even though construction only lasted about 2-1/2 weeks.

Thanks to Jake R., Tom G., Tom K., Tony W., Jim R., and Bill W. for their assistance with this project!

Robbie is nearly weaponized….


router clamp in foam 2I am nearly done with a custom bracket for my Hitachi router that I will mount onto the end of our Kuka industrial robot arm.  I cut everything out in foam first to check  out the whole scheme and save wear and tear on the cutting bit.

flange for RobbieThe software chain I used to accomplish this was lengthy.  I designed all of these pieces in 3D in Solidworks, created a Solidworks 2D drawing, saved that as an AutoCAD drawing, brought that drawing into Vectric’s Aspire, then created machine code that the Makerspace CNC router used to cut the pieces from a sheet of foam.

finished clamp

Finally, once I was satisfied that everything would cut correctly, I switched to 3/4″ thick Baltic Birch plywood.  This is a “nicer” grade of plywood than the stuff that is used in day-to-day building construction work.  This wood is stronger by virtue of a greater number of plies, and it also looks nicer.  I happened to have a sheet left-over from a previous project, so it was all good!

plywood sheet

Weekend Project: Planter Boxes!

Last weekend I made three huge, turquoise planter boxes for my rooftop deck – check out the quarter for scale.  Naturally, help from other Makerspace members was key, as I relied on JackD and his JAMbulence for help transporting two sheets of plywood (Thanks!).  I safely sliced ’em up on the panel saw, and then glued, screwed and nailed them together.  After applying numerous coats of outdoor latex paint and a bit of sanding, they’re already in use in downtown Milwaukee!

Planter_Box

Weekend Project: Kitchen Shelf

I’ve recently heard that the Milwaukee Makerspace has a reputation for only having members who are electronics enthusiasts. Well, in addition to the metal, wood, beerwater, whisky, fire, arduino, weldingoddaudiocasting, and numerous acoustic projects that I’ve worked on at the Makerspace, I’ve finished a few electronics projects here. My latest Makerspace weekend project is a shelf for my kitchen, pictured here with the Sad Bananaand three legged pig®.

Kitchen Shelf

Preschool playset remodel.

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My youngest son and nephews pre-school is tiny. Literally it’s two classrooms, but it’s a great environment for them both which includes identical playsets in each class.

Hundreds if not thousands of kids have played on them. Being built in the 80’s when building codes weren’t as strict, they were no longer compliant.

While the wood is still good, had been sanded well and sealed well there were a few problems.  The banister rails been deemed to be too short and the handrails needed to have another one put on the bottom under the other two on either side.

The choices were to surround the play sets with a 6 foot giant landing mat around the sides, or to raise the banister rails and add another handrail. A landing pad would have taken up far too much room in the class so I volunteered to rebuild some of the rails so they met code.

Because construction was going to take a little while (actually it turned out to be a long while, started before Christmas it was finished in early April), the rail cutting / routing / sanding was going to take place off site and then assembled onsite during a weekend afternoon

First thing was to take lots of pictures, and lots of measurements.

2 3 4 5 6 7 8

 

I did up some high-level sketches just showing how the rails would be raised.

 

9 10

 

The next step was to cut up a whole pile of 2”x2” rails to the desired height with a 45 angel cut on the ends to match what was originally there. The rails also had been rounded off with a quarter round router bit, so I did that as well.

 

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I knew there was no way I could match the old finish that was on the original wood so I decided to go with something a bit brighter and engaging for the kids mixing blue, red, green and white paints that I had my son pick out. Then it was just a matter of cutting and routing. Here are some shots of the wood after cutting but being painted. The coats ranged from 4-5 to get a deep coverage and then 3 coats of a clear poly to brighten it up.

 

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By some miracle the measurements all turned out perfect, which is nearly a first for me. We still have the bottom hand rail to make but that will be easy to do.

Nick Offerman, Come On Down!

Nick Offerman

You probably know Nick Offerman from NBC’s Parks and Recreation, though if you’re a maker, you may know him better for his woodworking skills. (There’s a great video tour of his workshop you should see.)

Well, Nick’s coming to Milwaukee February 23rd, 2013 for a show at The Pabst Theater, and while we’re sure he’s a busy man, we’d like to invite him to Milwaukee Makerspace to check out our workshop. We’ve got a nice collection of tools and a great group of makers who would love to show Nick some of the things we’ve made and talk about our love of wood.

Check out Offerman Woodshop for some of his amazing work, and if you’re on Twitter, ask @Nick_Offerman to swing by Milwaukee Makerspace and check it out!

Digi-Comp Making

Digi-Comp II
Photo by Windell Oskay

I love a good blog post! And I really love a good blog post about the process of making things! From selecting the proper wood, to cutting, laser-etching, assembling, and packaging, this blog post has it all. I’m taking about The Making of the Digi-Comp II, First Edition from our friends at Evil Mad Scientist Laboratories.

There’s a great/amusing comment on the post:

When’s the official air date on “How It’s Made”? :D

It’s funny because it is a long and detailed post about the process of making something (disclaimer: I’m a fan of shows like How It’s Made) but I don’t think a maker version of How It’s Made is a bad idea! Hmmm, maybe that’s what the MAKE TV show is going to be.

Snow-Globe Video

Just a minor update here from my recent Snow-Globe blog entry ( http://milwaukeemakerspace.org/2012/12/custom-snow-globe/ )

I made two VIDEOS about the snow-globe. The first is just a brief video showing the finished project. The second video is a longer “How-To” which includes some video, but is mostly a photo slide-show of all the steps I took to create the project.

For an in-depth step-by-step of how I built the project, check out the info I posted on Instructables. http://www.instructables.com/id/Custom-Singing-Snow-Globe/

-Ben

Custom Snow Globe

 

Well, I’ve been slaving away on creating a unique X-mas gift for my wife and two-year old daughter, and I think I got it right. They loved it!

I’m talking about a Custom Snow Globe!

A while back, I was working in the driveway on a styrofoam project. Of course, that white stryrofoam dust gets static-charged and STICKS TO EVERYTHING. I also found that the best tool for cutting it was my wife’s kitchen electric carving knife. When I headed inside to take a break and warm up, I was COVERED with styrofoam. My two-year-old girl looked up at me and squeeled “Daddy a Snowman!”.

Indeed I was. I imagined myself inside a snow-globe with styrofoam swirling around me like a snowstorm. But could I actually BUILD a snowglobe that would match my imagination?

I started looking at every snow globe I could find and set to work building one. I looked around and found a glass dome, used for light fixtures. I got two of them, and gave one to my brother-in-law, who is a clay artist, among other things, and commissioned him to make a caricature of me. Since he had one globe, and I had the other, he could make a figure that would fit inside the globe, and I could do the woodworking on the base, and insure that the globe fit that.

I headed to the local cabinet shop and talked to old high-school class-mate Steve about what wood to use for a base. He gave me a maple block, and I grabbed some scrap maple from the bin to practice cuts and routering on. At my Dad’s back-of-the-garage shop, I experimented with routing, until I could get it right, and routed a circle for the base of the glass globe, cut the wood base to length and cut a 45-degree bevel on the top edge, and routed a pocket in the bottom for the electronics.

I wanted to make a “singing” snow-globe, so I bought a singing greeting card at the Hallmark store, and then dissected it for parts. The electronics were then mounted on the bottom of the  wood base, along with a custom switch.

I headed to the Milwaukee Makerspace to use the laser-cutter.

Using the vector graphics program on the laser’s computer, I laid out an inscription for both the top and bottom of the snow globe base. I practiced on a piece of paper, and then when I actually focused the laser properly and had everything else figured out, I wood-burned the maple block, front and back.

I also used a solder station to add the momentary on switch to the greeting card electronics, so that the song would play whenever the globe was picked up to shake up the snow.

Next, was clear-coating the figure and the wood base. I used “Parks Super-Glaze”, a two-part epoxy clear coat used for bars, to completely seal and waterproof both the figure and the base, as well as to permanently attach the figure to the base.

Then, it was a matter to holding the globe upside down, filling it with water, filling the routed circular grove of the base with silicon glue, and flipping the figure and base, upside-down, into the dome of water. Once it was cured, the snow-globe can be flipped right-side-up, gift-wrapped, and put under the tree!

I’m glad to say that the project turned out just great! It was a bit of a stretch to my skill-set, so THANK YOU to the people who gave me a hand with it. Nothing quite like a project that runs the gamut from sculpture to wood-working, electronics, glass, water, laser-engraving, and more! But that’s how we grow… by stretching a little bit more every time!

Merry X-mas

From Ben the Snowman.

Lasers + Whisky = Delightful Wedding Gift

One of our members got married yesterday, and I crafted a fine gift for him and his wife at the Makerspace.  The happy couple enjoys whisky, and I thought that providing a tour might be a nice idea.  The tour starts at inexpensive bourbon, moves through wheated whiskies, and on to rye. The tour continues in Scotland with some easy to enjoy Sherry cask finish bottlings, and then moves on to rare, Islay and finally mature bottlings (25 Year old Talisker!).

I found some old mohogany baseboard that had some aging varnish on one side and some old caulking on another.  After cutting two 18″ long sections, a few minutes of belt-sanding had them looking great.  I used a 1 1/4″ Forstner drill bit to bore 0.3″ deep pockets for the bottles to fit in.  I used one of our two laser cutters to etch the name/age/proof of each of the whisky sample on top, plus a congratulatory message on the reverse side.  To bring out the rich orangy-red mahogany color, I wiped on Beeswax / Mineral Oil .  Check it out close up, while imagining the symbolism of things getting better with age!