I saw http://www.instructables.com/member/kcedgerton/ and liked the idea for wood ball bearings; but I didn't use a lathe because I wanted to make a really big one that could hold my weight. I weigh about 190lbs this week. Next week? Maybe more, Maybe less. :)
This is a Woodpunk chair. I have always loved the Punk Genre(Steampunk/Dieselpunk) and the design style. If you are interested in my approach to the design and wish to learn a little more about my background I'm going to put all that stuff at the end of the instructable. I just don't want to get in the way of your work, you have plenty to do when it comes to building this! I promise it's a lot of fun!!
I have been racking my brain trying to figure out the best way to help you draw out and make some pretty precise cuts. I think I have come up with some fun and innovative ways to help you do just that.
Whether you make this on a ShopBot CNC or just in your basement go get a pair of calipers I have a cheap pair of digital calipers that cost me around 10 dollars. Just make sure they go out to at least 3 decimal places, and measure at least 6".
First let's talk about material. This chair is designed for use with .75" plywood. I would recommend AA which is nice and ready to finish on both sides, or AB which is ready to finish on one side and clean and smooth on the other but not ready to finish. Take your calipers with you when you go shopping; measure the thickness at both ends try to find a sheet of plywood that is consistently between .69" and .72" The closer you get to .75 the tighter the chair will fit together. (.72" will fit snug and you probably won't have to sand too much.) Also make sure the board is nice and flat you can check this by looking down the side of the board if it curves grab another, I got lucky and found a good straight board about six sheets down. The people at the Home improvements stores are pretty understanding and helpful with this.
I've broken this Instructable up into two parts; Those who choose to make it manually, or those who have a ShopBot CNC machine or have access to one. If you have a ShopBot Read Step one then go skip ahead to step 10.
This instructable is rather simple if you have a ShopBot CNC and a copy of AUTOCAD 2012. But if not you will have to make this the hard way! Hopefully this will show what a powerful tool a ShopBot could be.
Okay, all you John Henrys out there looking to do it the hard way continue through the scenic route step by step.
Step 1: Materials and Tools Needed
Electric sander or Right Angle Grinder (for removing excess material for a better fit.
1/4" router bit
3/8" router bit
1/4" Drill Bit
1/2" Pilot point drill bit
36" wire or string
Brad nailer (1.25" brads)
PRS Standard 96-48-6 ShopBot CNC machine
Brad nailer (1.25" brads)
4 (2" long .5" bolts)
2 (3" long .5" bolts)
12 (.5" washers)
12 (.5" Nuts)
8 (2" long .25" bolts)
4 (3" long .25" bolts)
24 (.25" washers)
12 (.25" wing nuts)
4 (2" wood screws)
(21) 1" oak craft balls
Your choice of casters