Intro: Geared Rope Making Machine
This is how you can make a geared rope making machine. You will need basic woodworking sklls. Tools required: scroll saw, hand drill, circular saw and wrench set at the minimum. A bandsaw, table saw, drill press, circular sander all make this a lot easier. The ultimate would be a CNC router (ShopBot).
This is a fiddly project and you should be prepared to adjust and tweak as you go. I did not go into a ton of detail as this would become a 100 slide instructable. I will however add little tips that helped me.
I made it at the TechShop in San Jose CA.
Step 1: Templates
THe heart of the rope maker is the gearset. You can do a non geared version, but it will take a lot longer to make a rope. A geared machine will give you 1:4 ratio for a faster process, basically one turn of the handle will make your hooks rotate 4 times, instead of a 1:1 ratio.
I went with a planetary gearset design. I bought the template from here: http://www.mkdrafting.com/buyropeplans.html
Print out the templates and spray mount them on your 3/4 stock.
Step 2: Planet Gear
Spray mount your Planet Gear template on to your 3/4 stock.
Cut it out with a scroll saw. Take your time and cut as accurately as possible. Poorly cut teeth will lead to meshing issues.
Drill out the center hole with a 1/4 drill bit and drill press. You can use a hand drill but make sure you are drilling at a 90 degree angle to the gear. You do not want to drill off axis or on an angle.
TIP: Use a fine scroll saw blade 20T or higher. It will make for much smoother cuts.
Step 3: Ring Gear
Rough out the main shape with a bandsaw and smooth on the circular sander.
Then cut out your teeth on the scroll saw. After cutting cleanup your teeth with sandpaper and your dremel tool sanding drum.
Take your time and do this as precisely as possible
Your finished Ring Gear should look like this. The "bump" is where you will drll a 1/4 hole and mount your crank handle.
TIP: Cutting out gears is IMHO the perfect use of a CNC router (ShopBot) if you have access to one. The teeth will be cut perfectly and you will get the best possible mesh.
Step 4: Main Hook Guide
Cut out the Main Hook Guide with a bandsaw or jigsaw. This is the Main Hook Guide roughed out.
Drill your 1/4 inch gear shaft holes with your drlll press.
You can do fancy cutouts if you wish. I did not since my machine will be used by little children=little fingers which is a no no around spinning gears.
TIP: Drill only two gearshaft holes, drill the third one after your mount the first two planet gears so that you can adjust the gear mesh.
Step 5: Assemble Gearset
Assemble your Planet Gears onto the Main Hook Guide.
You will be using 1/4 threaded hooks and 1/4 Round Weld Nuts.
if you cannot find Weld Nuts you can use 1/4 T Nuts but you will have to break off the anti spin spikes.
Insert the hook through the front of the Main Hook Guide.
Screw on the Weld Nut with the flange facing the Planet Gear.
Slide on the Planet Gear.
Screw on the second Weld Nut with the flange facing the Planet Gear.
Tighten down the Weld Nuts with two vise grips. Make it as tight as possible.
I added a single lock washer between one of the Weld Nuts and the Planet Gear.
TIP: The sleeve of the Weld Nut needs to go in the 1/4" holes on the Main Hook Guide and the Rear Hook Guide.
It will be a very tight fit at first. Work the sleeve in all the way and then spin the Planet Gear until the sleeve rotates freely.
Resist the urge to open the hole with a larger drill bit. This will make the for a sloppy Planet Gear fit.
Step 6: Test Fitting the Gearset
After mounting up the first two Planet Gears put the Ring Gear over them and check the gear mesh by spinning.
Position the third Planet Gear in a way that keeps the Ring Gear teeth snug against all three Planet Gears. There should only by a tiny gap between the teeth (In case the wood swells).
Now drill your 1/4 gearshaft holes for the third and last Planet Gear. Add the Weld Nuts and check the mesh.
Mount your Crank Handle on your Ring Gears with a 3/8 carriage bolt, washers and lock nut.
Now drill your gearshaft holes using the Main Hook Guide as a hole template. Attach your Rear Hook Guide.You can use wood screws or 1/4 carriage bolts with lock washers.
Don't forget your 7/8 spacer blocks between the Main Hook Gude and the Rear Hook Gude.
Assemble everything and check the gear mesh again. Everything should spin smoothly.
Step 7: Winder
Mount your completed Winder on your winder base.
The base s basically a box with gussets for reinforcement.
Make sure you add gussets to the front of the Winder.
Sand off all the sharp edges with a hand sander. You will be sitting on the base.
TIP: You can attach the Winder with Wing Nuts so that is can be easily taken apart.
Step 8: Traveller
Now you need to build a Traveller. This is basically a sled that has a single 1/4 hook that you attach the other end of the string of the rope to.
Build the base like a open top box. You need to have a floor since your will be adding weight to the Traveller (bricks, stones, etc.)
Fully loaded the Traveller should weigh around 25 lbs. You will need to adjust the weight based on the floor surface.
TIP: You can make the vertical panel removable, so if you make your Traveller narrow enough it can fit in the space under your Winder Base.
Step 9: Paddle/Needle
Finally you need to make a Paddle. I used 1/4 inch Alder that I laminated together to make 1/2 stock. I did this because I could buy a small piece of Alder. I didn't want to bu a 4x8 piece of 1/2 plywood to make a little paddle.
The paddle template comes with the gear templates.
TIP: Drill your holes first then rough out the shape and cut the slots last.
Step 10: Making Rope
There are dozens of videos on YouTube showing you how to use the Rope Maker to make rope, or in my case Jump Rope.
You will find that you will have countless helpers who volunteer to work the Crank Handle on the machine.
For Jump Ropes you will use Acrylic worsted yarn. Three strands of yarn wrapped around each winder hook three times.
150 inches between the Winder and the Follower will give you a 71/2 foot Jump Rope.
This is the type of custom Jump Rope that can be made.