After a 9 month hiatus, Kenbo is back with a new build

Kenbo · Feb 8, 2015

I managed to get out to the shop today and after looking through the track pieces, I attempted to find some of them that were salvageable. After checking about 10 of them, I gave my head a shake and scrapped both tracks. If it's worth doing, it's worth doing right and I wasn't about to half ass the project now with pieces that were sub standard. With that being said......................TWISTED TRACK? WHAT TWISTED TRACK?

Kenbo · Feb 8, 2015

I did a bunch of resaw of some walnut and planed it out to the thickness that I needed and started in on making the new track pieces. This time, instead of doing all the steps at once, I just cut all the blanks for the track pieces and then drilled them and cut out the recesses in groups of 5. I then attempted to dry fit them together and if there was any twist at all, I got rid of the offending piece. I managed to get 21 good track pieces today and only scrapped 6 of the new ones. I have attributed the twisting to using my large floor model drill press. I believe I was applying too much pressure and causing the drill bit (3/32") to deflect in the stock, making the hole off centre. I checked and double check my set up for drilling and it was bang on. Unfortunately, I didn't get any more than 21 pieces made today, but I am well on my way to a nice straight track. I wouldn't have been happy with it any other way.

Here is a picture showing the twist of the original track. Totally unacceptable.

NYWoodturner · Feb 8, 2015

Welcome back Bro- Good to see you back in the shop. :good2:

JR Custom Calls · Feb 8, 2015

Dude... you've got more clamps than I have turning blanks...

Kevin · Feb 8, 2015

What do you think was the cause of the twist?

Wildthings · Feb 8, 2015

Kenbo said:
I have attributed the twisting to using my large floor model drill press. I believe I was applying too much pressure and causing the drill bit (3/32") to deflect in the stock, making the hole off centre

Kevin said:
What do you think was the cause of the twist?

@Kevin Just don't look at the pretty pictures - read the stories too it'll make more sense!! :cool:

NYWoodturner · Feb 8, 2015

Well i missed it too. I know he identified the twist earlier but not the cause. The dowels is my best guess.

woodtickgreg · Feb 8, 2015

Chubby checker.

Tony · Feb 8, 2015

You're sharper than me too Barry, I was waiting to see Kenbo's response.

Kenbo · Feb 8, 2015

I think that there were several reasons.

1) I think the larger weight and size of the 1/2" chuck and a heavy arm put too much pressure on the small bit and caused it to deflect in the wood.

2) I started off by using a 3/32" bradpoint bit. I noticed today, that the bit jumps around a little in the larger chuck until it finds it's place causing some of the holes to start off centre.

3) I didn't take quite enough time in the original set up to ensure that I was drilling perfectly in the centre of each piece. I may have only been off by 1/128th, but over 30 pieces, that's enough to twist a track to an unusable state.

I checked and verified my setup several times with test stock. Measured and remeasured. Replaced the breakpoint bit with a twist bit. Used a smaller table top drill press and took my time, making sure that I cleared the bit after drilling each 1/4". Seems to have worked for me.
I love the problem solving in these builds, but if I would have taken my time with the original, it wouldn't have been such a costly mistake. It's not my first track and I should have known better. Live and learn I guess.

Kenbo · Feb 14, 2015

I spent 9 hours in the shop today trying to get the new tracks done. I'm pretty pleased with the progress that I made today. I was able to finish drilling the blanks and cutting them on the scroll saw and the piece them all together to make sure that there was no twist. I then had to cut 120 new track guides and 60 treads. Once they were all shaped and sanded, I managed to get the track dry fit together and all 120 track guides glued into place. That was my entire 9 hours. I didn't think that I was going to be able to do it, because at some point in time during the drilling process, my drill press belt started to come apart. I don't have a replacement for this one so I made a temporary repair with duct tape and continued drilling. Luckily it held. Hoping for another awesome day in the shop tomorrow.
I've got a pretty special lady, who doesn't whine a bit that I spent all of Valentine's day in the shop.........but then again, we don't go for the Hallmark Holidays anyway.

Schroedc · Feb 14, 2015

About the belt, I keep a section of cut to length belt that uses a metal clip for emergencies. I've used it in drill presses and table saws in a pinch. Most farm supply stores used to carry it.

Kenbo · Feb 15, 2015

Schroedc said:
About the belt, I keep a section of cut to length belt that uses a metal clip for emergencies. I've used it in drill presses and table saws in a pinch. Most farm supply stores used to carry it.

I thought of that as well. The problem with this one, is that it is my table top drill press and the belt is only 1/4" wide. Most belts that I've seen are 1/2" wide. I'm just not sure of the availability of a 1/4" wide V-belt.

Schroedc · Feb 15, 2015

Kenbo said:
I thought of that as well. The problem with this one, is that it is my table top drill press and the belt is only 1/4" wide. Most belts that I've seen are 1/2" wide. I'm just not sure of the availability of a 1/4" wide V-belt.

Gotcha, I didn't realize it was that small a belt.

Kenbo · Feb 15, 2015

Schroedc said:
Gotcha, I didn't realize it was that small a belt.

Thanks for trying though. I do appreciate it. I might look into that for the other tools though. I thought I was going to be screwed yesterday and not able to finish the track.

Kevin · Feb 15, 2015

Keep some anti-vibe link belt handy. They are better than regular belts anyway. Not cheap but if you keep some on hand you'll never be stuck without a spare belt of any length.

Kenbo · Feb 15, 2015

Kevin said:
Keep some anti-vibe link belt handy. They are better than regular belts anyway. Not cheap but if you keep some on hand you'll never be stuck without a spare belt of any length.

I was going to pick some of these up from Lee Valley Kevin, on the day that the belt tore, but again, they are only in 1/2" width. The small drill press is a 1/4" wide belt.

Kenbo · Feb 15, 2015

Another 8 hours in the shop today. I managed to get the track mounted temporarily, but it still needs quite a few adjustments.

I started off having to make a jig to be able to glue the treads on the track segments. The hole is for the guides to fit down through.

I then used my set up blocks to get the spacing right and glued all the treads into place.

All 60 treads glued in. This took surprisingly longer than I thought it would.

I then had to start turning the wheels. These particular wheels have a 3/8" hole for the axle. I don't have a 3/8" spindle to turn them on, so I had to make one. I started off with a 3/8" bolt.

I then centre punched the threaded end.

And then I cut the head off of the bolt.

I then filed any rough edges off of the section where the head of the bolt used to be.

I then installed it in the lathe using a 1/2" chuck and a live centre to test to make sure that it was spinning true and not wobbling. So far so good.