My DIY Duplicator is Finally Done

[ProfessorM]

yes what Bruce said the lower the cutter, sled, the better control. You want the lowest height you can make it but still be able to get your hands on it and as heavy as you can stand it. Maybe take at least one sheet of that ply off the top of sled and put one under the base.
Make handles down kind of low so you can rest your hands on top of handles, fingers around handles, thumbs on back of sled, and wrists, and a little forearm will lay on base. Kind of a fonzy thumbs up, with the thumbs horizontal pointing towards each other. Make it comfortable as you are looking for downward pressure so handles up high are going to lead to fatigue as you won't be able to incorporate your wrists and forearms on the base. LOL making it sound like rocket science for cripes sake, sorry

[WoodyCT]

So I need to raise the table and chop down the cutter tower. And put some horns on it.

Thanks for the offer Johnny. I'm good on lead though.

I think I'll crank out as many soft-wood plugs as I can before surgery however.

[JFigliuolo]

What was your total layout $$$ if you don't mind. I've been toying with the idea for awhile, not sure if I wan to buy the PSI dup, or make one.

[WoodyCT]

I built this one after realizing using the PSI would be a big PITA, which takes templates less than 1/4" thick and can't hold a plug to duplicate it. It is really intended for pen turning I think.

Total cost was about $100.

Materials- 2'x4' of 3/4" melamine coated shelf board
2'X4' of 3/4" birch plywood
1/4" birch plywood for templates
Epoxy
Various screws, nuts, bolts, washers
Cutter holder and carbide cutter (most expensive parts)
Spray adhesive to mount photo of plug to make template

Tools- Band/jig Saw
Table Saw
Drill press
Belt sander
Miter saw

Easily an afternoon project for you handy guys, but I took a bit longer due to inexperience.

[Jigman]

Originally Posted by WoodyCT

I built this one after realizing using the PSI would be a big PITA, which takes templates less than 1/4" thick and can't hold a plug to duplicate it....

I started out with that dup. For templates I used a piece of 1/4 or 1/2 inch thick pine. Basically the profile of the plug. These were taped to the dup with double sided tape. Worked fine for small runs of plugs. If I had the ability to build one like yours, I might have opted for that instead. Looks pretty cool!

Jigman