A Portable, Human-Powered Lathe Designed and Built by Scott Lewis Illustrations by David Heim

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Richard Robertson
5 years ago
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1 Tailstock Toolrest and banjo Drive belt guard Headstock post Headstock spindle Page 1 Metric dimensions Tailstock post Drive belt tensioner Drive belt and flywheel Chair Bicycle pedals, sprockets, and chain Lathe bed Frame brace Chain tensioner Frame base A Portable, Human-Powered Lathe Designed and Built by Scott Lewis Illustrations by David Heim

2 The Frame Page 2 Headstock post. Space posts apart Front view Side view Lathe bed Spindle hole for bearing 44mm 44mm 228mm 152mm 140 mm 100cm 168cm 122cm Notch deep 88cm 37 Front view Side view 53 Frame brace. Length is approximate 74cm 34cm Tailstock post 122cm Frame base Notch as needed to give clearance around flywheel brackets

3 The Tailstock and Toolrest Page 3 Brackets to support dead center are shown on page 8. One bracket is threaded and one drilled out to make it easy to align the tailstock rod. Hole 19mm Banjo upper arm All bolt holes 9mm Tailstock outer section 3" Hole 13mm 95mm 57mm 46cm 36cm 57mm 27cm Hole 13mm 57mm 23cm Tailstock wedge Tailstock center section Banjo lower arm

4 The Flywheel Assembly Page 4 Bicycle wheel axle mounts to brackets bolted to headstock posts 51cm BMX bicycle wheel Inner rim. 66cm outside, 61mm inside, 13mm thick 46cm Outer rim, 19mm thick After assembly, turn a slight crown on rim to help hold drive belt in place. 66cm Divider, x x 102mm long. Trim for tight fit between wheel and inner rim

Attaches to headstock shaft with hose clamps Turn a slight crown on pulley to

5 The Headstock Page 5 Bearings bolt to headstock posts. Center pulley over flywheel 1x8tpi threading Pulley. Attaches to headstock shaft with hose clamps Turn a slight crown on pulley to hold drive belt This end can be reverse-threaded to hold a grinding wheel 183mm approx. 53cm Cutaway view of spindle shaft and pulley

6 The Belt Guard and Belt Tensioner Page 6 Belt tensioner pivots on rackets on headstock posts, held by bolts that also hold bearings, Belt guard side Belt guard cover Front view 133mm Side view Belt guard held in place by brackets bolted to headstock posts 'Hole 52cm 56cm Belt tensioner arm 83cm 86cm 81cm 83cm 17mm Belt guard cleat (Attaches to frame braces) 89cm 32cm 133mm Belt tensioner roller Belt tensioner roller bracket

7 The Pedals and Chair Page 7 Drive sprocket at flywheel: 70mm,16 teeth Cranks, pedals, and chainwheels salvaged from old bicycle. Frame members cut down and welded to bracket that is bolted to pedal support board. Height to center of crank, approx. 229mm. Chair back support Chair seat support 2 82mm Chain tensioner stop block 1, screwed to frame base Block and wedge adjust chain tension Chain tensioner stop block 2, bolted to pedal support board 35 Chainwheels: 28 teeth 38 teeth 48 teeth (Largest wheel not used) Seat & back rest 19mm 60 56cm Bolt holes 87cm Chair base 100mmm 46cm Chair base block Seat support cleat mm 60 61cm 32cm 21 73mm Pedal support 202cm

8 Brackets and Other Hardware Page 8 Headstock bearing from Princess Auto ( Part no Top view 203mm Tensioner/guard bracket Flywheel bracket Side view 117mm End view Flat bar welded to rod 102mm 13mm Side view 25 mm 1" 1 19mm 25cm 102mm 79mm 54mm 94mm 127mm Tailstock bracket. 19mm nut welded to 4" plate. Leave 1 nut threaded, drill out the other, to make it easier to align dead center. Dead center 32mm Toolrest bracket 38cm approx. 19mm threaded rod 13mm square tube welded to bracket Coupler nut sharpened to point 9mm Toolrest Banjo locking bar. 13mm threaded rod, with nuts attached. Handle to suit welded to rod

9 Cutlist Page 9 Part Qty. Length Width Thickness Notes Frame Tailstock post 1 88cm Lathe bed 2 168cm Headstock post 2 122cm Frame base 3 122cm Frame brace 6 100cm Length approximate. Cut angled ends to fit Tailstock Center section 1 46cm Outer section 2 Wedge 1 23cm Toolrest & banjo Banjo upper arm 1 36cm Banjo lower arm 1 114m Flywheel Outer rim 2 66cm 66cm 19mm Cut out inner circle so rim overlaps bicycle rim Inner rim 2 66cm 66cm 13mm Cut 1-in. ring Dividers 6 102mm Length approximate; cut to fit Belt tensioner Belt tensioner arm 1 56cm 133mm Belt tensioner roller bracket 2 Can be plywood, MDF, or metal Belt tensioner roller 1 Belt guard Belt guard side 2 86cm 19mm Belt guard cover 1 83cm 133mm 19mm Plywood Belt guard cleat 1 32cm Part Qty. Length Width Thickness Notes Headstock Pulley 1 Chair Pedal support 1 202cm Length approximate. Cut to suit users. Chair seat support 2 56cm Chair back support 2 87cm Chair base 2 61cm Chair base block 2 32cm Seat and back rest 3 46cm Cut angle on one edge. Seat support cleat 1 21 Cut angle on one edge as needed Chain tensioner stop 1 32cm block 1 Chain tensioner stop 1 30cm block 2 Chain tensioner 1 39cm block Chain tensioner wedge 1 231mm Taper to point

This go-round puts kids in orbit

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