I can tell you that my plan is to use the machine to create hollow casts using urethane molds.
I tried to make the directions as obvious as possible, but clearly my day job is not as an assembly instruction director, so please email me (firstname.lastname@example.org) if you have any questions that arise during this Instructable. I heavily stress relying on the schematic as your guide.
Step 1: The Supplies & Schematic
The schematic I created for the roto cast shows you where things are going to go, but doesn't get into the details. Most importantly, it shows you where the secure and loose joints are going to be.
Here is what you will need.
Strong power drill
Full set of high quality drill bits
Pliers or Leatherman
Glue gun (w/glue)
Metal/Plastic epoxy (2,500 pounds per square inch strength)
Bicycle gear cutter tool
2x 20 inch 2x4
1x 25 inch - 2x4
4x 5 inch - 2x4
2x 18 inch - 1x1
2x 16 inch - 1x1
2x 14 inch- 1x1
2x 12 inch- 1x1
2x 4.0 inch - 5/16 inch rod
1x 4.5 inch - 5/16 inch rod
1x 8.5 inch - 5/16 inch rod
1x 3.5 inch - 5/16 inch rod
3x 4.0 inch - 3/8 inch rod
1x 6.0 inch- 3/8 inch rod
1x 12 inch - 3/8 inch rod
1x 3.0 inch - 3/8 inch rod
10x 5/16 inch stop nut
13x 5/16 inch nut
5x 3/8 inch stop nut
5x 3/8 inch nut
Box of 4 inch wood screws
8x 3/8 inch washers (probably will have extra)
8x 5/16 inch washers (probably will have extra)
4x 3.5 inch 22 teeth bicycle chain rings with 4 pre-existing mounting holes, NOT 5
2x 1/8 inch t pipe connector - to support the rotation axle
2x 1/8 inch elbow pipe connectors - to use for the crank
12x L flat brackets used to strengthen joints for frames
3x 3.0 inch flat metal plate with 4 holes in it - this comes in packages of 4, and would normally be used to secure to pieces of wood together. These plates should be able to bolt into the chain ring holes. You will have to drill a whole in the center of the plate though, as there is no existing one there.
14x14 inch piece of mesh