Duplicator machine

Duplicator machine

Here’s a duplicator machine I made. It duplicates table legs, and by putting in a small table it can do flat work as well. This will allow us to duplicate the same product over and over. If you look you will see four wooden gears in the front. The small gear on the left is an indexing gear. And this is used to position the work piece to match the piece being copied. We made these wooden gears and they work well for now. We will replace them with metal gears when we install a motor.

Once we upgrade this will cut your own pattern. Such as rope, twist or spirals on table legs. This is cheap to make and has unlimited uses.  If you decide to make one like this. Then you should us a solid rail on both sides. The way I made this one is OK. But if I push too hard it will move a little. If you would like to see how we made it or make a comment.


This is one of the live centers we made for the duplicating machine. It works great, a little hard to push the live center back in when the wood swells. It still works good for something we made real quick.

We made this out of 2 x 4 blocks. Pick up the centers from E-Bay. First you need to check the cutting height of the router. Then cut the blocks to match. Drill the holes to match the bushing and the threaded nut in the two upright pieces. Install the threaded nut to the inside of the back upright. Then use a piece of all thread with a small nob. And cut the length so the all thread will touch the bushing on the left upright. Then use an epoxy to fasten the bushing into the wood of the left upright.
 Make sure when you buy your live center that the shaft is not tapered. Once the bushing is in place then slide in the live center. The base has two slots cut about 2″ long and 3/8″ wide. So we can use two bolts with wing nuts and have some adjustments when putting in a piece to cut.

Duplicating spindles for a chair was a little harder than I thought it would be. I had to make a few changes and some modifications and this is what we can up with.
  Changes to the prototype
Theses are some of the changes we will add to the duplicator. When we get ready to make the final product.


When cutting with the larger bit everything went good, but when I used the small bit to cut the detail I couldn’t hold it steady. So I took a piece of plywood and cut 2 slots. And then clamped it so the cutter was center of the work piece. This held the router in one place. Which made it easier to follow the piece being copied without pulling off to one side.


We removed the center gear and attached a drill to the side that is to be cut. This gives it a lath affect, by turning the spindle at the same time the router is cutting. This makes a smoother cut.







On the first pass we used a round bottom bit, this is to remove the the bulk of the wood and start to rough in the shape of the piece being copied. The piece being copied is not turning only the piece being cut.




We used a small tapered cnc bit to do the detail work, we also found the faster the piece turned the smother the cut.  After the cutting was complete we took sandpaper and sanded the spindle when it was turning. This finished it the same way you would on a lath.