The CNC Wheelwright

[Burkhardt]

Here is another one of my wacky projects....(series of 3 picture posts)
I want to build a functional wooden garden cart, something like a 2-wheeled wheelbarrow and I want it completely made from wood, without screws, nails and bolts. To be sure it can be done I started making a wheel over the weekend, kind of like the old wagon wheels, 24" diameter and 16 spokes. Lacking the iron hoop (and having a CNC router at hand), I made the rim segments interlock with dovetails and crooked the spokes to achieve a double dish spoke layout for better rigidity. I used simple 3/4" pine board from HD for cost reasons.

I think it came out quite nice. Now I need to make another one and build the cart box.

Cutting 2 of 16 rim segments (1-sided):
https://lh3.googleusercontent.com/gFM3nfzkLenCLxUk0N2knVeDkmlj9bvC-zqA2gaq4N_m-9XZver_kXIG9xFtflIHrZ-aoldErVQ9Uz9QipKLF9C6R64R77BpILvshTMGVxsMiuu8jr5KL AHP9vQKd_aKMs-OWjI8LgXaaUr0Ekjs8OjDgBh_zno4f3IJ2PKh4WSzcOQ-zNJrX5QN6-QxEXx7tl_QwCYu3AK9gA_1yPLfvI0p_gD54gf3jzzuZ7Y8Kvms 9TI0tX-ROWK-qmuSp5MVUI_JUKpXU8meUSfMtv37a2APIge4vVK0VbR_VodJzG 8lqCmv11lDe0zj3WNxOPHpK2ii0MZJmNPaP5d26H4QZzNPYFp5 8-HcV594HrNQtks12yuJroFEjKgDoHUtFqMaFOvBPlImWVTh9m7f j9L89TidOZUS9UqRKTUbyOuHW9ANAc_T2JMoZKXMZP9ZfcY-9LVOUKAadjo4gpQMnh4rT07MJDXLtLHzt6MZEQofTDPlLV1n2Q Gs_W3Qouo393xHo8YBRfsgghEZOUAYiizuEwh1iLPm2t3w_kMU fJ4bOb_FtXiQ2XeM9TkgvL6YMHgdUzDVpIXBg80Zq50ybJaax_ TZkoqMPKz0J3svun4GK2NUznuSCUNN=w1828-h950-no

Custom vacuum pod to hold the segments:
https://lh3.googleusercontent.com/rf8xYuXdAMvWTHvONi3aJLRgQh5MVC4t-8Ol4UHQJoP6Q2HZnD2k-zS1ySSXEGC5Grerl82D7wEIXonI9o0REJs-l6-u5Zfntxy0vvwssL0rzfOSwhkpkC3ZkJIzZJV0MX2rAP4jRm5B2 BsLaxLJwtNLZiV_rQecgiik5Gv5CRPzhVYW7pgcRuJs_SEE4_4 CwUs-yziu_FcTLGlJqgcVthkvdnZmioYnKqjuSIY6WoQkNq3DVJiNhK A7xbIZGtUBtJkl1S0EshQ9fuql1OtpaptU-qDVboeX_eBS-xdXhFlKmrr9r1pkv0ekyH0RPdG-Lc9OCItb9bs7WxBfPvSaiwvyXcc-VAgZAHnCa0gXP74M6BPFtCC6asY8dTsfxjxSjOy9A67yvZQZfg qHZFyGFjy7FuV6QDm9PyC2eVx9P65QRIOqeNWDy5yfCwbv75bo fCEVa0FPOmbeUB3avWWMF2XeT4gpu28voPqulYcAtlgzA9ZTb0 XABxQ4YD1HNRqR-mEm2Iq7El5XF8nAnbEJcBU2N8mSpukq6lj_X6Bm0zhlFo-zc-PFQVhCj14ixqDaGn8_aFO1225FMupDMtGgJqTrR5rJ7GDQweel-lu529dxXvkD=w1920-h930-no

Cutting 2 of 4 hub discs (2-sided):
https://lh3.googleusercontent.com/HzkQPMEdrHMxQ6BF3yuRMH7HO2pErktVNEoLTeI5whmPnuTQfQ MKz6suZHYFkEeaIH6UQU4bC9-r7QxJleDtaS93Ir6tmtbQ6OCNrOAZ387G88qLbsvBbtBlFSSvw P9GfIoK0FD-9SjxBOvZh0Whp9FiFepjJkR8mzSrTOpb9ULl0e4XzvAJ1nXRsB qvxu3B7QvwT7ow1KHnYCQxvW1Ap-SajlY3jGiWtIKAWG8AH4kIczxnIw45Mo_S7HBwf3gvblF2G-AFmm1lTQbhdTcmORuSpwLrRXKo4KEJ7PON3nS2c00n4VqHk9Rs 4cEWNDTZfvs6RtZ1jxRd4P5YXLbGzuCTFtJ3qNu4LQGLaDXWDB-g6hLg1QRNgiBwxbrr4hqoEKf_5tOvdXA_rn7LJEisaZjgth6zU rAtID8wxmKC0SkMXdJvxOhJ2P1GwxLk7-R_4ScxOo6BYHjitpgqAQvYSYNnq-fYjiPwtNP8BN2FmyNEq57XHOLxntcJSqqc0TfVcVSpM6NfrtIU OeXiZpgfXG-zVEhIEn6AuIHZPn8JNmKctdwqQ5UHgjKmN2BnyFxRorOB2y8KA 5MrXJeUpL45gHbWOoiEfyju0QrE_EdI59N4pbLO=w1676-h950-no

Cutting 4 of 16 spokes (2-sided):
https://lh3.googleusercontent.com/mud8CLNHwLPkYZsKxqryTRzpROcBBqREVbvSJNWx7ZtZ-W-q6cEhBVnJbl7hoHPcIk60iDb0VeHDWoOG_TSINSKMJfZ-jKav2dV9jTQFrki8Bozlq73zxDxqeKyElLVzNcpVNubyKgSFwa _CC71XkoiVcKRK12rAVCtzixFLv0zEHlcFMwbNTqU4Inji489I I_sifrzutxO0wpJwxdSz0dIFaDC_vl6-WZ5LX7miWJyLSWsFtYd_9KpTzBU_tjwX7tQtQtM6pyV7Qhsn9Q Eb4q1uOIMohdzr5uGBvP0HsnQdTmcq_Zfp0PwMZaVxBWl1nX2k-40iNNtohMUB2vgwWCxT6dr73V8DhGDKBiNJAFHSFtlu4jNUHuS IboXR04M-b-JauMRuQW54g_xsTXXojE7fDPxUOKb7SrbMrFn84eAR-gCYrt_D8Y02raX3EfwxORD33FbSP2kzDWiSk2jZwwilLfuwAZG BgpqrfZ1w3p9z6tQk1VUDhTwbnIXWOrc3Tkn2hxLbtD8hYmVTm-6Gtzi4HWnkFhwpOF6iLQlgExc1SDCzzHJWf9LDXGGgqfq0tSU0 6W43iI0k2t_2BHT9T6WfcDNQP9LT9k0fXf4FswWYb_Pu=w1777-h950-no

to be continued...

[Burkhardt]

All parts completed:
https://lh3.googleusercontent.com/wrYZPYDi0aUvwdGYjFi90eXqfA8ys7ye9-ewSHrLM7YfqjefqJe3jJTowRpVT8r3zGRWmeN2YtmmcDGbo0nY cTycjHk6vC93Re5dorX9BKg46-0w285gOiq56OJCE94D7Ou1JE3vbyZVj1dZRQnsRmr4v19I5-UIXiVqYBP_i7oAACTBvKCz67nZC4fZnOILl-l-YmIoLP-m5vTtjYtRYjxSFlU7ynFuSzFf-fLKVNEvQutfYvebVI96p0kTqR1JHsLRxqUcyDNinpiEaw8nziA hGdbYDQcfHyRkDoR5P_hyFXC5HpxnSk23_2Vm1ochqT169ucW6 Jtx8r6KPH9J8Dj6p3DVIRZtaMHC0l02OkJyNAgdSReVwV7OLk2 fSkVThuWQeHkjHhCzWr5Kj0dYUpP7khr_H8M9f8HBlGCwNlTVU UTjMHqZeGyuH0fb1Ko2PiSZJpRJFvvUa5nygdOdfgmWCP2jza9 TniYXJenh-SNXaMygAyaQ1JYoAGdAwlYSln1ajhSHdAOKgelWBW7fRQmW6gW EKvtXa_iGhtNesTZnT1t_HZ8es_1v0tf2CSKIn_0_swyIcYmUE HW5We8A_Gj7sQohVh4lByubkQF8_-8xOg3c=w1576-h950-no

Starting the rim assembly:
https://lh3.googleusercontent.com/1yVBFvA_qMLGXdb9ANZPFjXduI8kuaPvYNTqJWZfJ7MuxmoZCb cSuhsha65GUL2C3uBUWkU_YSE7OhNbxUF6mUbbVXQpdabGVeL7 n5GFVE9NC_CG6Qm95vsm-wrXGX7FBnWxuE5U66RyEqzeLpFzfcOBUa-_Q3H67PIrOtAPQIipAakxcFyfUgRuWKKctoFt_jcRVfWk-CPIYNvEEIJdQeB73k2Cd1U7LWrZo6skN9AgowMawNI7hwngQfX dKnUTMvhslFyxaKl7FqhaO4lq2FTx4A04v3LyUAlgpo7Ji_Miu XNbRTEyAyYiS-HbX0thh2Igv_ZcUjJ8M_Em3ZUwQM3tH2xKF8uY1SAX_N3KNMWs 3S2jVD8jLcITIAkMDUif6b1UPMB0h5bI_oX9ncdz7510AGQP6m 6AuBMGyUfOY-X-1alq2LMStgGFONw5TZnedfmzHIcF7VzHWfcL4eys3tclvaILVJ bb_mudK1u9vtFtkVQooaRuDGHugjoWrPPxa5EMj5qk2v5G0PKl Uc7eHW9bd03s-ximOmcAcKCs9jA8UqTK3ocSgvybmS2sbrP8ODXtQblxDWQBIlO aqHNEYnspzU7bperQ-SJt5gCZ1ZSyp831=w1261-h950-no

First side dish of spokes:
https://lh3.googleusercontent.com/SjUF-XbvvXhHNQehD0Mil7Hhjz38F_USxn9w0rKJKw1Fxryer4RPqF4 Qvvlw07vO-SA7Ji3oDY1P5II2_eu4Wcfw5M1osjY6VM5Bq0-D80bPUb0Od_gpSyI0B4PtBDJeMomL-Gjdp11j80Ez7ygXHR7v-OP6ONQD9gWQ63SO_tUQ067cn9WaOtDr5Mvn_5yvyGkAlD9h-lMN3GuAv-zXb2ho_33MrmQWUCLOxviJNypqp_Avv8MgIF-hbS4groMi2NbACvsNtYd8DEFS_H-gwk6NHn1vMYsVB9SVKqgguK5uV3gMnSbMwKi-rYJvXtxSnSsiZNDro5zZhZI1w_gin3oCTisbQ69xD80FWXmi_L qgMddydsMMNb8ICX2_mZLxR8Qsg-6WVHYa0fny9doLgFJt3KK90sYO2lH5N4zwfctNbdXNthblPI2o muXEv4YQkbdZ4eVTG4Jx8COEo2yJULA4tErLjPdx_4Pb9AFuRJ DPeT0Gid20zozFSdKfrrTc5YJwNilrqg0DPgBr_rROevJY6raW HTrCgajNNzoN8uFTWy-eezyncJQ0QPX6J5pvoA0fdwec-ArrpqcgMf3cGtGbQ4Y7eB5KL8RLz9EDnkBjrcpk=w1347-h950-no

[Burkhardt]

Trueing up and chamfering on the lathe (sometimes it is good to have a lathe with 24" diameter capability).
https://lh3.googleusercontent.com/LKiJct2C9S15hNHBgxik8Hqbmw7BrN5WMBhwT33IbvTvJYTc_x FMsuBaTzVpgqkcylryicj50nZGZ3_iNxYduiI6bPNmzFhyTO_d yLy_IuUQeRg0n38Bo9nwlbo7jOtUUoGmQ87mso2bvYiSgbJf2i w_u2ZdPvAnZaf_RSE3c4CN9o5CPS7LUhUR4e-Nvh9F2fkKWKG2wahlAr58YiPj0JR55js9R1sUCQ7QZVCfaJzRH O91t9FY3cJyA1u-YQncf4ojShMnzllUzTgakkKdYcutZlTxls6Z5xL50JJ2M-S3WJ_qlKh5NLKS8KMq39xgCOegWHLUjLHIArtoBOY4RySytlwO fIHlSfoIgLasfeIGs8If1wdacv5wFbjrwHXkh0ZwwL8nKeuXOH TRc6VaBlRFo_TW-JebfAn2XAph0grruVrsP2rhdCTY534m4T9bvAS9MvUuCqFdU5A ONsPSRkGCAduCc2YKdYvW3fg8fwSi0DrSEfn0Kgrs6NS_9g2ol 3XQFcWsUronb7UzrCXug5PptjdxOyvsw9No7pOr6tHyvaEX_p4 H16-zWB-F5uKWtRuXcJLxVKcPW_8QJwvbs9NaIdX1ZcUJBqACW15bf5Zid 6Ga=w891-h950-no

Wheel complete and finished with unpigmented stain:
https://lh3.googleusercontent.com/CJyUd9jIVoCHEXV3RHmTJIIvBqUHPOoiUhG4wx94TAcpNNny0e GdMyw8mTjClRhnWrYQIfbLsxRzp2AsZgdDoqe8g51Im7VlAgtf fRpkrdf5ID29jZj9kt39Z8TlLcf639-VECHXb81krSSVawFY-reERPoUsLO1U_4a--5O5ig7dbpXnQVp-3NDaPHapc1_Gm9cj5-ulhpvmlbD1BPQza3DG_Ik1fiKw3aGFqPG2xcSwlhHUKz_DPWCi kJ0oyaYL67RwSAqgpVLYDP1yYlEgn1McQ6uRhZeJgzK6Za5x3H 7wYr7IBXz1o4DXfDQRPof96QqkM6CgL4fiqrR_2mdKo8n4YrBA LvHWXXBOVaVH5Avs9poZQTT7ogRHPy5xL1O1OzZ6M-VvcHgCL58LfVCOjM6aocK2wHXNzXAeHTdlNVHjVmR1eYiRZ9ue BSXiu8ZxFCglrKOx8o-qZtS5q9gniyk-Y0h9kmuqIPvN4whnS7zC4VUUUy4ETsEaSXyFNLiTZjzrESiqr2 6z_iDse2hcWHz7cHEMKv4AydnIh2hz8pJNjJ7ALi0NQxNQzCDl P-FpcdUQsieTuuTFGSDqkmSrsrJtZa-QaK9SUaxAU6oGOE3Ir8Z=w808-h950-no

The rim is deeply grooved to install a bicycle tire:
https://lh3.googleusercontent.com/jg36jt7NQjP07j75NAbYLTUEkNYBmtQ0bQf-rNj9iZJRGR9j0G4Xptqbc0CaKKdDBH3tPHWUmY3_pgNcGtvg9V DUyQ-p3LwaxJAY64FocdTkTAAJpH53zq-NfZsVulc-b5UdIzBb-8ocNmFEt4z1LpxX6_EjSCEOdsgAuijJxlVfZ1KJw4TaeuKscPL JMFlgefnh0w9U3BhAL3z6HkjdPtxtA66JIiZ-C0Ts0n1Re0y0KZ_HS_2m_kIfvG0bD0VUCOH94yQ9AprYP8YARn tY9zjFPEqaR61G17ns7l3MoAeKlbUl3_fX0fwew9DdF0Is8vLx ZXfU6JWlXRByhC_oTSGbiaKIIvIFruzVHpV55sxrmCQkFykVVX 9KeTfnVDwJ_1kydmZDiZRI6tXRyXCY81u26--G6TaXKJVORfSS_cZlv8NCGvRUmN9CAUTYLbDiAlKltEv_KTqOo iO4uBwHb0-FhnqJGmRWFm2uyp8l7NA9N7hAPlrD6L8IjklF9f0Jq2-MoqE4LQqk3yoBaWfKSYC49MHGNfZe0E6suyX1uV5kZ6R4NS_7G GltldcTwAWlrfafw_fqEQyUsQm-jiCDqO3SaxMab0mIfMxteiYJf7SkM7H4=w511-h950-no

[mtylerfl]

Very cool project!

[Keith Larrett]

That's awesome!

[steve_g]

Impressive!

Just out of curiosity… how far out of round was it?
SG

[Burkhardt]

Thanks guys :)
I wish I had the skill to build such a wheel with hand tools but for now I can live with the CNC method. Looking at old pictures, the wheelwrights back then had their special machinery as well.


....Just out of curiosity… how far out of round was it?....
The eccentricity was excellent, maybe only 0.02" which is not really surprising since the spokes fit into the pockets snugly and there is not much reason to be out of round, given the accuracy of a CNC machine.

I had bigger trouble getting the wheel not to wobble sideways on the lathe but that was more a work holding issue than an accuracy problem of the wheel. I had the rim assembled on a 1" thick sheet of plastic so it was really flat. For the next wheel I will skip the lathe and rather flip the rim segments over on the CNC to do the chamfer with a V-bit.

[Bob Eustace]

Absolutely brilliant concept Gert! You never cease to amaze!

[Burkhardt]

Found that video, amazing single purpose machinery. I really love watching the mortiser.


https://www.youtube.com/watch?v=3Oo0yFp9gvU

[scottp55]

Beautiful job on the dishing and Joinery G. :)
Did you make for 24X2.125" tires with no flat inserts, or solid tires?
Maybe buy tires and check fit? (although you've probably already done that)
I LIKE! :)
scott
WOW, Talk about your big iron!! I think I'd braid my ponytail and stick it under a hat in that shop though! That mortiser is a real weapon:)

[phil_o]

Fantastic - thanks for posting. Great pictures too.

Phil

[Burkhardt]

......Did you make for 24X2.125" tires with no flat inserts, or solid tires? Maybe buy tires and check fit? (although you've probably already done that).....

No I have not done that yet and I did not even know such no-flat inserts exist. I had originally planned to do a solid wood rim only and staple a thick rubber strip to the outside. But looking for a suitable strip it occurred to me that I could try a real tire with tube as well.

The closest fit for the otherwise completed design was a (somewhat exotic) Schwinn 26"x1.75" with 597mm bead seat diameter (only little smaller than the 24"/609mm OD of the wheel. I have some tires coming in and hope to get them to fit. If not, well then I have to come up with another idea...

[scottp55]

I only mention no-flats because my new wheelchair has them, and I have a garden cart with 2 flat tires:)
When I had bicycle shop, always had problems seating Schwinn tires...enough so I bought the Park tool which you can probably make yourself;
https://www.amazon.com/Park-Tool-Tire-Seating-PTS-1/dp/B00781X57O

I'd definitely buy the Park tire irons in plastic,as I'm still using mine for the wheelchair from my 1985 bike shop:)
Less likely to mar your nice work;
https://www.amazon.com/Park-Tool-TL-1-Tire-Lever/dp/B001B6NFH2

Dish soap(or your car wax?) on the rim edge will help the possible struggle...baby powder inside the tire before seating and spread by rotating tire and spreading with thumb, will prevent binding between tire and tube from the rubber to rubber static friction.
You'll come up with something:)
scott
OH, thorn proof tubes should be readily available out your way, and work well as they are 2X+ wall thickness, and less likely to get pinched with tire irons.

[chiloquinruss]

A few years ago my wife and I took a cross country trip and one of the highlights was a chance visit to Hansen Wagon. We planned to stick our heads in and see what was what, well we spent 4 hours there. Everything was being built just like the original. What a place.

http://www.hansenwheel.com/

I watched their wheelwrights for some period of time but I never saw them make anything as cool as what you engineered, offset spokes are you kidding me! Unbelievable! Well done. What a terrific job of tool-pathing, just amazing. What software did you do the layout in. Russ

http://www.talkshopbot.com/forum/attachment.php?attachmentid=29633&stc=1

One of 13 barns full of historical wagons - his library for building replicas!
http://www.talkshopbot.com/forum/attachment.php?attachmentid=29634&stc=1

[Burkhardt]

A few years ago my wife and I took a cross country trip and one of the highlights was a chance visit to Hansen Wagon.

That looks like an interesting place indeed. Given the price they charge for a wheel, my project may even be cost-effective :)

As for the design tool, I use IronCad for such stuff. It is similar to Solidworks and unfortunately similarly expensive. The outlines were exported as Autocad dwg files and loaded into VcarvePro to make the tool paths.
Below is the CAD image. The only change was that I did not let the dowels go through but let them end in blind holes from the inside. But the dowels are anyway redundant, the wheel would fit together and hold up without just as well.
29635

[chiloquinruss]

I sent pix of your project to Rick at Hansen Wagon and he was duly impressed. I am still blown away at the offset spokes, I bow to the master! :D Russ

[myxpykalix]

Seems to me you found a way to "Re-invent the wheel". Actually very cool project.

[Burkhardt]

Dish soap(or your car wax?) on the rim edge will help the possible struggle...

Thanks for the tips. I got the tires on and it was kind of a moderate struggle. Valve stems have extenders. But I learned that even plastic tire "irons" are a bit hard for a pine rim. And I learned that 40 psi is a little too much and will require some wood glue...

Anyway, I have it pumped to 20 psi now and the rim holds up. But it is a bit soft and I will probably replace it with solid rubber tires.

https://lh3.googleusercontent.com/cpq-b41-BJNtwRbAvulBzsHjZ0hoIn19H-gxeJp78zp2yl_Ia4KtVo4Dj25PWrcWFndwTzPewJVC7HZE5bzU D8jFWq2tlQZXVCwCMpy6M44Ic_d-U9HAP7vkv3i6R9DdOuHS7k9sooADV7--FtpluKYo_fgbn996KX7gD_HyAX0eP4bKUse8HkV8so2e-KsVo8TU4KZJaNlh30TgrRp9aI6WXbAVx1V4gOh77LSMdN3Ihap m-82JwySD5VJiL8TPBtl6rWWUD9qGpGqyQDP6kH0OeQoDab7qNAB RaY23K5LIdFjIOe5yIyUYDfUyWK9EiVu7ei51sfeUoimp7Y1wd mbDmCA8BojUmddcPsbBzzF_C-o5JsgJKIDWHV3FWcHVlsQKfrZhDysDJgjPgL1IpRX1ZTVWUTyD fRFGKJo0-f4mBaKvVkzQMgMf48A_uQ7640z7JMiHYhaUTXmxJNsqXFrUasm tPo3CG9qFp3T-NnhT_hR_NK3Kywh_1OOHr_eevrtwXFlyxlvX_6jSU3lyZiVCr7 65dQViMVuDmyZ3_CKmlSKl7rocz9I_dgpSTyXUq_HzQR_Wuy9C aNVp7DhrV4ipTRGGqdfgAGuDK5D_0EyRNSKbSKbq=w853-h950-no

I worked on the design of the cart itself. I should go together without screws or glue and boards just lock with 4 dowel rods. It will probably look something like this:

29649

[Burkhardt]

I sent pix of your project to Rick at Hansen Wagon and he was duly impressed. I am still blown away at the offset spokes, I bow to the master! :D Russ

Thanks, I am just an engineer who knows how to use CAD and a CNC machine. But I am making progress on the craft side. After 40+ years of woodworking with crappy tools I finally bought some decent hand planes. What a difference! Next will be a set of good chisels.

[scottp55]

Yep, was wondering about Shrader extensions, and sidewall pressure. If they weren't Schwinn tires, you probably could have just used your palms and thumbs to work it on.
Cart looks really nice, but handle looks to short? Knee bumper/shin kicker walking forwards, and Achilles destroyer with cart behind you?
Love the no screw approach, really makes you think:)
You should try Lie Nielson planes....no backing off of anything, and ready to skin a fish straight from the factory:) He's a nice guy also.
Quality tools with a razor edge are a joy to work with!
Really neat project Gert! :)
scott

[Burkhardt]

...but handle looks to short? Knee bumper/shin kicker walking forwards, and Achilles destroyer with cart behind you?......

Good point. I am hesitant making the thing too bulky, given my limited storage. But you are right with the short handle it may be less practical.
Maybe I go for the following design as a compromise. Can be adjusted for tall or short people or folded away for storage:

29650
29651
29652

[genek]

Thanks for the tips. I got the tires on and it was kind of a moderate struggle. Valve stems have extenders. But I learned that even plastic tire "irons" are a bit hard for a pine rim. And I learned that 40 psi is a little too much and will require some wood glue...

Anyway, I have it pumped to 20 psi now and the rim holds up. But it is a bit soft and I will probably replace it with solid rubber tires.

https://lh3.googleusercontent.com/cpq-b41-BJNtwRbAvulBzsHjZ0hoIn19H-gxeJp78zp2yl_Ia4KtVo4Dj25PWrcWFndwTzPewJVC7HZE5bzU D8jFWq2tlQZXVCwCMpy6M44Ic_d-U9HAP7vkv3i6R9DdOuHS7k9sooADV7--FtpluKYo_fgbn996KX7gD_HyAX0eP4bKUse8HkV8so2e-KsVo8TU4KZJaNlh30TgrRp9aI6WXbAVx1V4gOh77LSMdN3Ihap m-82JwySD5VJiL8TPBtl6rWWUD9qGpGqyQDP6kH0OeQoDab7qNAB RaY23K5LIdFjIOe5yIyUYDfUyWK9EiVu7ei51sfeUoimp7Y1wd mbDmCA8BojUmddcPsbBzzF_C-o5JsgJKIDWHV3FWcHVlsQKfrZhDysDJgjPgL1IpRX1ZTVWUTyD fRFGKJo0-f4mBaKvVkzQMgMf48A_uQ7640z7JMiHYhaUTXmxJNsqXFrUasm tPo3CG9qFp3T-NnhT_hR_NK3Kywh_1OOHr_eevrtwXFlyxlvX_6jSU3lyZiVCr7 65dQViMVuDmyZ3_CKmlSKl7rocz9I_dgpSTyXUq_HzQR_Wuy9C aNVp7DhrV4ipTRGGqdfgAGuDK5D_0EyRNSKbSKbq=w853-h950-no

I worked on the design of the cart itself. I should go together without screws or glue and boards just lock with 4 dowel rods. It will probably look something like this:

http://www.talkshopbot.com/forum/attachment.php?attachmentid=29649&stc=1when you put on solid wheels run your bath tub full of hot water and soak the tires. it make it easier to put on. Also if you take the spokes out of a rim, and your wheel is just slightly larger You can heat the metal rim in a large commercial oven and it will just barely go on with a rubber hammer. After you have it on and Straight, you can take some flat head screws and screw it to the wheel. Be sure to put a tube guard on the rim before putting on the tire and tube. Very nice job.

[scottp55]

Good trick with the water as hot as you can stand it...used that a few times,and works great on some solids. :)

G.,
What's the geometry like when you tip it forward on end(as if you were dumping stuff or shoveling mulch out)?
Would it be beyond the tipping point, so you could store it up on end?
I'm glad it's not me doing it....I'd worry the design to death and never get it built:) :)
Always like seeing your stuff!
Does your brain have an off switch? :)
scott

[Burkhardt]

....What's the geometry like when you tip it forward on end(as if you were dumping stuff or shoveling mulch out)?
Would it be beyond the tipping point, so you could store it up on end?....

Scott, good question. According to the CAD it would stand on its end. The COG (indicated by the small cross-hair) is beyond the wheel point of contact. But I will probably keep the folding handle bar anyway. I think it is a nice feature.
29656

One thing that came to mind was filling the tubes (mostly) with water like what people do for tractor tires. It would make the cart 2 or 3 pounds heavier but may reduce the pressure requirements for a stiff tire.


...Does your brain have an off switch?...
Not really. I invent and develop things for a living (not wood stuff but industrial instrumentation like flow meters) and when I get home I just keep going with the fun projects. Sometimes I wake up at night thinking about a new idea. I guess it is kind of a curse but a kind of enjoyable one.

[Burkhardt]

Some good progress over the weekend...I cut all the main parts for the cart, finished with teak oil and assembled. Everything fit together well, which is kind of surprising since I had to cut the six lengthwise boards in 2 parts with index dowels (47" boards on a 34" machine). The wooden axle washers and clevis pins are still missing as is all the handle and rear foot parts.

But everything is held together with mortise and tenons. No screws, nails or other metal parts and no glue except for the wheels.

I see a usability problem, though. My wife said I made it too pretty for real garden use. Maybe it becomes the cooler stand for patio parties. Would be kind of a shame.

Partially assembled.
https://lh3.googleusercontent.com/vS6CWXZEfiB5qR-OAHcz7UYVBOeIHMwKe5XlktKS0czRs2K3AZeLH81TjpPJVMapL 8kMOaJsyMkncwM3z5KbAe8T7t73nLhXAEFTYavVWcTlYQ0sW8S _dYh7ywejdqq5MFwxf-1dbcpcxRmagBWQBLW0uqPGSQCchzbyf9vl0nqEDdjml31h4RHR cDmqhpPrPe7bZz7HdskartfP2vVKLX4qJUceNNsWVn4nRd3RY3 oXjIbv5vz1t0qM3Sofu4kd-M9XxwmPMXiQKXBYAhUmkzjICZyMB-SjLhzaiy1AtpXg7jpY6w3UsqXy6pEJz2JOslPjO1FAfp7fYQq-Kas_4rNmGUkA_uG1gBIKjTtCEaeaoc4jxeb9zf_XesxgDl3Cyg ZI_Q9j8yH-bVlRkFkbVJetvHBUuvp0Ln2AmRwtQkxo2w2JlQrJ30RIGiPM_F QfYLQZFbH9YQBlWyA6nMcO6cUmfSLOVmdp_jcdVIJFBah6Le43 0rXJd1hRKBx-jaNK5VEosUKXhPUbWaMGTvy7o3sTc9PQVwZ7JJJYGGx8aX2wDx 9yuvRjXHFNcBWHRhTXi0d0XwxjKgkO7MKGOHQi5bIeHP7NX0Km 3yi6dWij-KMxfDe6fPvZ=w1442-h950-no

Complete cart box, locking dowels still missing:
https://lh3.googleusercontent.com/kh_yRfGhqo5zsfmirqiq1QlzsWyg2FWEv1m5z7Tp5xZgrG_Wro i0sYk-T-6WanfU8d-8_RFpfsRliVDGTC5SdcRNnpC1Zl45Ilfrn9bb8MeDGtA4k7qC5 tn3EPpQ_rZU5CDoLYhMUUbh1ZAhlZhVoF7KKWWSSK6KUhUFOk0 cS9gsqE-dVKnxGauofa71ZI7N7BGbeCrd3FkYCkHKYS3tWOpxXBwvRnY2M Mh1jtx-hpclbhsVdIf1T8HqUDll4oonZCpt0qkRI79mjxBkew2Az3litY b4vDZqVUfMXovX74kDxRdOoemHZsnWv1SnagT-bIvdmArSW82_S8Cmqykhdge_BgfWqZdrPQICfEabZHN4ZZIKVz 6ekkg-RoTEX_PoPnFkanLzQ6wrrISU8Ot1_MsOCPt7eAzJm7A7ucp2sK I9PNisaNwUEQ7dO0ku1G39gkvRUD2cZPbT85vTBh3ih7mGtQ9R uOaXx6JfaVICP635bvqAdWzrcwZWXJLbn_BwDBRF-bMhW85Vzy-pA3maOcrUGLAFm8moT20ruzBn8pIyP1juX2TXON-z7aXULU9kBIuCJxPBpr8L8IiOkUdPcZgTUGPapwqJk1NBLSG3g RGKvtZi=w1408-h950-no

Another view:
https://lh3.googleusercontent.com/y1A1LjPu1s1yoBlbpB3UIV4bfGkVw-UhxZteMc1jEbzUiQuX72w54H63nf2a15WBLgj9qRbHM526SviZ qHUHqdBhEs4m_PpSltCKr_WvwQQRDPN6JUqFhAKGfAvg0SQN6c aMiwPMbRQi_8qv-HEa89IDif-fevqgdEDnghHxrRWve-VJOwmXTdSUn7FJnG3qfCHaJcrg12mtHa4r1ARqvvArVotJteCz NTBvY2RLAEC3w4Fr3ghCezifTcAR505CrHbU4Hhh7XeM_XLA6x 9fFK4MFtVeLaSp9Do0Cla4I5Fu47g-6ibZBYUm4aZYNfMqbUPSTU_WfjmZjbrrdtMaJywOfJew5n8P9s ADvjsRPrNUt044S3kjalp1nMwAGQP9czXvIx183tiPlmSGD2IW QpDEJD1ScZtqvlGt-Cyk9ghjlSNSnSAb7tdN1SVOvLGon51JQI5yJeP2a1JzLoeRrgT notLu8GZbNQ_P2H1ybMWflg5CDHiveUWDidtgTpibMFZrWtRkp KzsvabZrBvg4ojzqJpvSHk7Hvv6F46sf9PPZBph43LjOgruz3z CCaLW6JjTD67hHe91QJpS3F5OPlU18h4pR-2EZKzWnfhXEHhXNIik=w1292-h950-no

Scott, it does stand on its end:
https://lh3.googleusercontent.com/In_hPIaTeb5FJVSEc6feek1XHXz_DxcmgSTIFaruQymLp2zFbx 7k4jpuNKtAqk2kZ_UDStIrkupM_e2bj2WZUtSw03oM4_cy4dIl sbCqKMjOqUjgo_uNn3XszR0eWw1SaRGY3Ej7_i1L-iIFcbx6lwdqsRZPcmJ5N6jGjXuAnTGpCGgClDOIhNkQtngsZ-CC_3YjnNifuv-keuVVYyLPGUOqH7_2w_8GGSfPZ09-VUHPCHWD-a7QPyVA_xoESCttjlkdEbBpvCMfhBx0oMAwUgQ3O2J2DiNFLKx XfG01rVkdRTT09K72tfSUYMlxZBItN4mDjmcBbvANR_Oc5QIvI QzTKtGG6frTkL1IF0VuWBJfw6Uttc0skni22xm3szz4gulCi__ Hft92uFUcOYXfIOz22-5qxQ0w2Jp8bTyAYzHW7eoifdILX84y7s7xcX34hL_IqcywOzX1 LefVRPUAh_cJchEjWjCZgFvnyX93JpJ3V1Wx28XE7FmsIBe9MS SNdXi_fm2QUyqtvaByx9ECaG0xLZgAZu3NqDVLEraxt1Ro0F1-0nBrI8tCzIhhR6QY8HSmJs2FntNKqsEjmnnxTbtkL9gixCC3Zt smXzIbfNtw-N-q=w712-h950-no

[scottp55]

Golly G. Wiz(ard) :)
More intelligent questions once caffeine hits:)
Flower flourish excellent!
scott

[myxpykalix]

"My wife said I made it too pretty for real garden use" She's right!

Maybe put a tabletop on top with a hole in the center where you can stick a patio umbrella in the center....

[tri4sale]

"My wife said I made it too pretty for real garden use" She's right!

Maybe put a tabletop on top with a hole in the center where you can stick a patio umbrella in the center....

Agreed, I'd Line the inside and use it as a flower pot.

[chiloquinruss]

Well I'd really like to reply to this thread but I'm speechless! My goodness what a work of art. Without hurting yourself, please pat yourself on the back, well done! :D Russ

[scottp55]

It would be a definite "Eyecatcher" at any trade/craft show, and a good way to bring your displays in(and easy to make it a display stand as well):)
You going to heat soak wheel axle in molten wax? 50/50 Mineral oil/paraffin "wood butter" would make a good "grease".
I'm looking at Teak oils now that the one I did the house interior in is discontinued(West Marine)...who's Teak oil did you use, and did you like it? Fumes?

Funny...I was thinking that with a Marine battery and car stereo components(Fosgate of course) it would be a great audiophiles mobile music center for shop or garden:)
Anachronistic as all get out, especially if solar trickle charger was added:)
Wonder what shape speaker cabinets you'd make:) I know...Off the Wall!
It will get comments no matter what you use it for!
Great work Gert!
scott

[Burkhardt]

Thanks for ideas and the praise guys :)

I would be hesitant to make it a static fixture like a flower pot. I spent quite a bit of design effort to make this a functional cart that can actually be used. I suspect, being pine it would not survive long exposed outdoors anyway.

Scott's idea with the tradeshow cart is interesting. So far I have not participated in such shows but may do that later when I retire.


.....You going to heat soak wheel axle in molten wax? 50/50 Mineral oil/paraffin "wood butter" would make a good "grease"....
Have not thought about that yet. I suspect even being "used" I won't make that many miles and if needed the 1" oak dowel that serves as an axle can be replaced.


...I'm looking at Teak oils now that the one I did the house interior in is discontinued(West Marine)...who's Teak oil did you use, and did you like it? Fumes?....
I used the Teak Oil (Watco brand) because I ran out of the Danish Oil and the clear stain. But AFAIK Teak Oil is anyway only a marketing name for slightly different formulated Danish Oil. It is however more amber colored which was O.K. for this purpose since the pine will darken yellow/amber anyway in short time.

[genek]

Actually they hold up pretty good outside. We Made one to use at a show. We gave it to a local Farmers market and they have it out side and has been out side for several years now.

Thanks for ideas and the praise guys :)

I would be hesitant to make it a static fixture like a flower pot. I spent quite a bit of design effort to make this a functional cart that can actually be used. I suspect, being pine it would not survive long exposed outdoors anyway.

Scott's idea with the tradeshow cart is interesting. So far I have not participated in such shows but may do that later when I retire.


Have not thought about that yet. I suspect even being "used" I won't make that many miles and if needed the 1" oak dowel that serves as an axle can be replaced.


I used the Teak Oil (Watco brand) because I ran out of the Danish Oil and the clear stain. But AFAIK Teak Oil is anyway only a marketing name for slightly different formulated Danish Oil. It is however more amber colored which was O.K. for this purpose since the pine will darken yellow/amber anyway in short time.

[scottp55]

Ah, Watco. Yep, I imagine you're right in that case, But there's a very wide range of other Teak Oils and I was just wondering. Thanks!
Didn't know the width of the hub, so I was just thinking dipping the ends in like a Mason jar like I do buttons would be easy..as once wood is warm, the excess wax drips off/cleaned with paper towel, and then as wood cools it sucks up all surface wax.
Probably right on the mileage:)
Russ is right that it's a work of art:)
scott

[James M]

I think the other contributors are right! It would be an eye-catcher at a trade show especially if you highlighted the flourishes with different colour paints.

Very nice project! The wheels are outstanding!

J

[Burkhardt]

Final update...project completed.

https://lh3.googleusercontent.com/ugDXeqMG05WDp0qyozOOpOTkKlwU_-5OnDhdLUFYO10U-f_HxwjRVdcwAGFrEUsxb71kf-LqvA9rlUZ-cB1FgsBundJXGG286eNo2b1Xc4hZy8L-hrFzOquJrZ6rBg96YAfEsm_FgViGGg8o7wHOakqvKd-YATFDFdMR4N8Kepo9_5AJhCLirj4ls_x00HKgNQ94fgL1d1e24 wB96g5ZVY4rNeU6CEcSYYrxH39G90PrfjMsncu-hUgTv--e2rHi3mTVNjNUILlTL09Zf9d6UEH86589rPfrhBWrxmgACRV3h ZAQnh7LU0RqPAndQpAegYf5ygQATefMwnm0lLF5QyDLjx2wBYT 9d1ucO5w-ODdmLp79Kgpu3uX2D0f3HI3FJ9TZDoK_ob_XQSynypCjiq8fsS T1JGL6BRyAXP_a5Uf-uy9JRfZU7MlWxsRx3DD841HZN1a6POrYJxFQ9epIqI0_u_QF9s jDi-3KEo-iTIvm2Z8TpjwADfQAiL5h2ZLhDDvDpKxc24nq6sUftegU8hYy5 w2cpolbHTQNdVJWcR_wThTj8_gh_0BMtywbwW-UVV7J0JEjPSNGn9BGII54VITwE5swPiKZhTwl9i1i6i4o7OU-CDou=w1223-h950-no

Rear view with legs down:
https://lh3.googleusercontent.com/UC-C_EVs8AlKnHsk8zgXgIzhH3e-w4Z8uK5shgdxDWEOhbZPpDfpaUKmwtm8-5H3pIPO-UAdzjyh2OIMlF7G9KGtI2AGWfSxXL7TdawnHoY7q7nbie_AUk_ bo4IEyH-GAK2dzKcTeDqNdLT9SopUY0RwFL75INCDgdrGb1AaPGs0uTQFT xVLArQveUDJp9nEVHdpKMw0ZaCRCYQqI-s7oDNvkae9x4VrHu5ABGR3XoMkEDjPQB9Y_mGXsKFupt8mB4sM xn5MDPsDdMDmwSRlaZeQGyCyQwA0XElga0_M_KipO4r0xyyMgd JMOTea5bnVnZ9d__nHkI0t1Be7nDRav4guOb1ft0ny9MD2pw7j 45t444tGziXdwZFGxfTlukHDScBCmJ4o6z40W-0WBcmTIPC1x24PS5kl4eYQWZg_zAMi-tQvr8VcPl7R_IKtQh2Yz-ms10Xw6dW5uDvpMgD7feGcwhe3JgU38RqymTNyW-jTBImfx0cQfuZdnu-5eY0uozr4F7DvTlOOouJyUL5r-Ux4k_XcjzdSMSrDiL6Y8o1vwKCDtBPZcmw4MbsUmk7vr97S_z0 0UKXUzQXU0Tczy4ekUihVD6y36onIfYiN8Oqo6js7u35U=w160 6-h950-no

Legs up:
https://lh3.googleusercontent.com/7QUPnjwh7abhQeI8Cpr0ex-VZalyAopWq1bKR3vuFW9XSUP4DdhK1kcqhvz_M-BetSeqSVu1H-HAQRR_7kzYTeq2EtYRPsVAuh1IXk-xMFQVBzQNEgZoZrl-jKrh1cL_34eHZOqcA1F6hZbCc5dEgyYJM38lufAdZFFeLhEZE9 WRjV88CS-W9p460A9Eoy1X-6O5fQTjtCLPSPFZZxwZOPfXTFZwgTBBw6F4bXdtnw0hETo3Icv 98Jpfb51xcO_TOhRryoHt_9hjZeqcjgzZ1NFAyhuE_RSigKxIw g4bpQsXk7w95v1tsYiHgE5oTFAr_6b5c4nJy8yvfODK9lSjsGh d75zRFu-t2xk5MPKL3I-OVTnz9P3dKE7_GKNELSC-82UNVnj54JFCd2dvNtQSt74_ji8dWLj77E9g4_I8I_q0SLsTkV Mm1BlRMNG9wg3t0XTx3wlfBI84qOGsmMIHvjCkWee679TMUV92 pWsoXNlAhikA5M2NMYpYo119jCCLfAx1abwo4e7Zu_ap5wU_ej B_GaeI8rT3MSbYR7pieSPcYrjCqtSoJ6VubXYRuVMj3URC5Ja2 sHJp71Jm-lSf7te5MGynOKz1jp21dGoFOyYugMt6=w1425-h950-no

Standing upright:
https://lh3.googleusercontent.com/6rJZV6qehyD3lK1WPZTPnordd9BJY2gpOXkJwn_hWi1XiEloHq Yc8f2mflqdc37VReTEOn0AIwjqwWr-dX2t-veD1PuXynkSN4NypldcwObc3v60rA4MLLoygUHEAKoZ_lWfG9R ZiSr4f8EWgcI7NOwqcSphoVYTllEmQJd3YMjGMGNQOiIID1hdk 6968MGj4wHiaO8ym4FIWmbDVx5rh8oIMNuH97pdxz4M98UWTFX nrOHeLIu6hLBa40l3AOb0glo5GLUoDGQp61EeEQJyTut2ROmlx ohnPi9f_qRtzCgLCpHjRvdpKMO_JkK-7BqdBCgDyLZfXnQ_wGmkx1H0WyuKJoNRW-WLYDIHG8CSCsv5ufjnyGijFwN7DBLQ21bZl6mStzxX3qLPnIC-Z72p9qWXIXrqam5WOzS-JqfSnDWtmtxBHRpoZLqZWDGHBLn70znc3rI-POCEQr86g9eav4Izsnwb0h-KCCv63fPCPiB_L2ZCWxuoa_iKAlD3L52_i6-l3fkIO6fP-ZfM7g5RI4klj8Wi6MeRYS7AEg_3nVX3u8wKlzzTX-jOOXG6VosC76n9Lw2uYXMtXjMJUf8CdhrxqEGMusulvcVbMUfz OhietWse=w596-h950-no

[scottp55]

Purty!! :)

[James M]

The design and the finished product is beautiful! Well done!

[mtylerfl]

Excellent result!! Who did the Tole Painting? Great work on that, too! Chisel brush?:)

[Burkhardt]

......Who did the Tole Painting? Great work on that, too! Chisel brush?:)
Well, kind of 90-degree v-bit brush. It is not really tole painting. I just colored the vcarve recesses with acrylic paint like a coloring book and then sanded down the mess I made overpainting the edges. For a while I feared I screwed it all up because the sanding dust of the excess paint mixed with some of the oil finish to an ugly smear. But continued ROS sanding with a coarse and then a fine pad cleaned it all up. After that I reapplied the oil finish to the exposed fresh wood.

[Brian Harnett]

Very nice project.

[myxpykalix]

Absolutely EXCELLENT!!!!

[steve]

I think you've just re-invented the weel, very cool!

[Burkhardt]

Also posted on the Vectric Vcarve Gallery forum...

I had several people ask for the design files of the cart and specifically the wheels and I have no problem sharing that.
Just be aware this is not a trivial project, can not be done on a sloppy machine and may need some iterations to get it right (I had to re-do a few parts myself).

But otherwise, enjoy! It was a fun project for me.

You will find the zipped download with a few hints on my web site under the tab "Garden Cart" http://www.tailmaker.net/

You can use any of that for hobby or business purpose as you like. Actually I think the wheels could be made cost effectively when making a whole batch and if the clamping/vacuum holding is customized/automated.

I did not include the file for the v-carved flourish because I have no idea of the copyrights.

[scottp55]

Thanks for the files Gert! :)
(also downloaded the Guilloche and box clamp again) :)
scott

[GeneMpls]

Very generous. Thank you Gene