Downdraft Table for Sanding and Powder Coating

George CarlsonNews

A new Downdraft Sanding Table was built in The MakerBarn.  The table has a large squirrel-cage blower from a 5 ton whole-house air conditioning/heating unit.  The blower pulls air down through the table top, filters the air with a two-stage filter, and blows it back into the room.   The unit moves a lot of air, and can be used for cleaning the air in the finishing room while using the stationary sanders.  The hood allows the unit to also serve as a powder-coating spray booth.

The unit is 60″ wide, 30″ deep, and 65″ high.  It was built using pre-finished birch plywood.  This is the same type of material used by cabinet makers for internal shelves on kitchen cabinets.  It has a tough epoxy finish that is easy to keep clean. The table top is a grid made from the same plywood.  There were over 400 dado cuts made to produce the egg-crate style grid.  A four foot LED lighting fixture makes the booth bright and easy to work with.  The entire unit was designed and constructed in The MakerBarn.

Bridgeport Milling Machine for the Shop

George CarlsonNews

 This machine will help open new possibilities for makers at The MakerBarn.

The machine is in excellent condition.  It has a 48″ table with movements of 36 x 12 inches.  The Sony digital readout has a resolution of 0.0002 inches for very high precision.  Installing the machine was easy, except it did need quite a bit of cleaning.  It is now up and running so come visit and see what can be done.  Instruction on the machine will be on a one on one basis making a small project to help familiarize the maker with basic metalworking methods.


The Wide Belt Sander is Ready

George CarlsonNews, Tools

Today Greg and I extended the dust collection system and connected it to the belt sander and the router table. The sander is awesome. We currently have 80 grit belts for fast stock removal, and several other grits up to 220 for finish sanding. The machine is somewhat complex to operate, but still not hard to learn. If you want to get qualified, let me know.
We will be changing the V-belts and adding automatic controls for the air supply, but the machine can be run right now.

New Sander for the Woodworking Shop

George CarlsonNews, Tools

  • Big belt sander  –

We are always trying to improve The MakerBarn, adding new tools and materials.  Recently we had a very generous donation of a Sheng Shing SDM-15 wide belt sander.  This machine uses a 5HP motor to power the 16×48″ sanding belt.  The belt oscillates back and forth, which helps lengthen belt life and avoid streaking the wood being sanded.  It can sand a 15″ wide swath, but being open ended on one side, the operator can rotate his panel and sand a piece 30″ wide!  The machine weighs about 800 pounds and is very solid.

When we received the machine is was complete, no missing parts.  It even came with two copies of the manual.  The machine was built in October 1996, so we just missed its 20th birthday.  The sander was also in good condition except that all the internal pneumatic tubes had disintegrated.  Not a single line could be found, they had all turned to dust.  The pneumatic system is somewhat complex since it operates the belt tensioning, belt oscillation, and the emergency motor brake.  Information in the manual was sketchy, but I was able to re-plumb the pneumatics and now they work as they should.

The machine runs well.  Unfortunately, after a few minutes of running, the sanding belt broke.  Not an unexpected event, since the belt was probably many years old.  I’ve ordered new belts in several different grits, so we should be in good shape.

What’s next?  I need to install a MACS system and a main power switch.  Strangely, the machine was never built with a main power switch. We may want to change the two V belts at some time, but for now they should work.  Within a week the machine should be ready for use by the members.

New machine at The MakerBarn

George CarlsonNews, Tools

It's here!  The milling machine is now at The MakerBarn

It’s here! The milling machine is now at The MakerBarn

The Sieg Super X3 is now at The MakerBarn.  It has a longitudinal travel of 17″, crossfeed of 5.75″ and the head can be moved 15″.  All three of these movements are displayed on the DRO.  The quill has a travel of 2.75″ and has its own digital readout.  We should be able to do some very precise work on this machine. What’s your first project going to be?

Soon I’ll post a shopping list for those expendable tools each member may want to buy.  The shop will provide clamp-kits, vises, chucks, collets, and other larger items.


Digital Readout for the Mill

George CarlsonTools

The Digital Readout system has been installed and the mill is ready for action.

The Digital Readout system has been installed and the mill is ready for action.

In my opinion, no milling machine should be without a digital readout (DRO).  If you ever had to use an old machine without a DRO, you would be amazed that anyone could produce good results.  Counting turns of the handle, reading tiny numbers on dials, making sure all movements were from the same direction, and having to compensate for lead-screw wear; none of this is necessary if the machine has a DRO.

There several different technologies used to build the linear scale used to determine machine position.  The DRO on our mill uses high precision glass scales.  Inside the scale housing (spar) is a long strip of glass.  The glass was coated with a fine layer of chromium, then fine lines were etched in the chrome as many as 50 per mm. The reader module, which is attached to the spar, slides along the glass scale.  The circuitry inside the reader module shines light through the glass scale and using a pair of light sensitive detectors can “read” the glass scale and output pulses to the display unit.  The display unit counts the pulses to determine location.  The small computer within the display unit can provide many different ways to use the position data. These functions are beyond the scope of this blog.

The machine should be ready for installing in The MakerBarn sometime this next week.  Look for upcoming classes in machine operation and certification.


The Stand is Completed

George CarlsonNews, Tools

Sieg SX3 on stand

The stand is finished, well, until we decide to make some improvements.  The stand has small iron casters to make it easy to move, but also has leveling screws to level and lock the machine in place.

Now we await the arrival of the digital readout (DRO) system.  This consists of a display units and three glass scales.  The linear glass scales are packaged in aluminum spars that protect the scale and keep it free from dust and dirt..  The readout device has a resolution of 0.005mm, which is about 0.0002″!

Milling Machine for the shop

George CarlsonNews, Tools

A new addition for the shop.  This small milling machine uses the same type of tooling as a Bridgeport style mill.  So it should work well for use until we can get the larger machine.  I will be building a stand and installing a Digital Readout, so it will be a couple of weeks before we can move it to the barn.  With this machine we will be able to machine plastics, wood, and almost any metal, including steel.  Each member who wishes to use the machine will have to supply their own cutting tools.  This would typically be a set of end-mills, which is not too expensive.  When learning to use the machine, it is not uncommon to break or otherwise ruin cutting tools, so it’s best if each person is responsible for their own.  I’ll make some sort presentations at upcoming meetings about operating the machine tools, so stay tuned.

Sieg Super X3

Sieg Super X3 Vertical Milling Machine

Why do you want to be a maker?

George CarlsonMaking

Alpha Geek2

My father was a cabinet maker and the son of an immigrant farmer, so I guess that’s where it came from.  Why would anyone want to build it, when you could just go out and buy it?  There’s something about the feeling that this object, what ever it is, was made by my hand.  I guess this is part of the human psyche.  Without this basic human need there would be no scientists, engineers, artists, or philosophers.  On some people, this need is just a bit more intense than others, so here we are.

In this day and time, the support of making is needed more than ever.  We, and our kids, are bombarded with commercialism.  Kids need to be taught and shown that each and every thing they see online or in stores was made by someone.  Guy Lautard  wrote a series of books called “The Machinist Bedside Reader”.  The books are a collection of anecdotes and how-tos related to metal working.  In one of the stories he tells about a delivery man who is picking up a package at a machine shop.  He asked the machinist, “What do you make here?”  The machinist replied, “Gears”.  The delivery man looked amazed and said, “I didn’t think you made gears, I though you just bought them”.

So get out in the shop, or your makerspace, and make something.  Even if it’s just a pile of chips.

There’s good stuff in old junk

George CarlsonBuild Log, Making, Materials

Overhead projectors are not used in schools anymore.  So you can usually get them for just a few bucks at the online school auctions.

If the projector works, it can be a good way to enlarge objects and trace them on pieces of plywood.  But they’re even more fun to disassemble and scavenge parts for future projects.  My grandson and I took two projectors apart this afternoon (we have more).

One of the best finds is the fresnel lens located just below the glass platen.  These lenses are about 12″ square and have a focal length of just a few inches.  Just what you need for solar energy projects.  Be careful, it’s easy to start fires with these.

Fresnel lenses from the projector can be a lot of fun

Fresnel lenses from the projector can be a lot of fun

Other parts such as power cords, power switches, limit switches, super bright lamp holders, fans, metal pieces, and optics can be found.  The projection head almost always contains a high quality first-surface mirror.

They usually come up in auction in groups of a half-dozen or more.  So if you’re not careful, you can end up with a garage full.  Check auctions at and