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Baker Roundel Development Project

Started by karsthotep, Jan 08, 2014, 03:31 pm

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Theta Sigma

Mar 10, 2016, 02:42 am #105 Last Edit: Mar 10, 2016, 02:45 am by Theta Sigma
Quote from: davidnagel on Mar 09, 2016, 01:25 pm
Quote from: Theta Sigma on Mar 09, 2016, 03:10 amI tried something similar with a mini router.   I did not have much success on the roundel front using that method.

Dang. It did look like it'd need more effort involved.

I wonder, and sorry this isn't quite intended for this thread, where the original roundel plug came from? Is it possible it was a combination of a few flanges/surrounds etc to create the shape, or was it built as per the way you are, from plaster of paris etc etc.

I have often wondered this myself.  Other than clay or plaster methods, I can't help but notice the similarity of the roundel profile to that of chair rail moulding.  There are special router bits made for this, and to me it looks like a combination of at least two bits.  Here's and example:

"I just put 1.795372 & 2.204628 together." - 4th Doctor


Mar 10, 2016, 05:41 pm #106 Last Edit: Mar 10, 2016, 05:41 pm by galacticprobe
Another possibility is that they could have turned out a master on a lathe, and then made a mould from that to cast the roundels in. With all of the fancy gouges and paring tools they have when working with a lathe, it's possible they just picked certain tools as they turned the block of wood. Or someone could have had a nice moulding bit cut from some steel stock and sharpened it, and then used that to turn out a master on the lathe.

All speculation, I know, but it is another possibility. (Isn't it?)

"What's wrong with being childish?! I like being childish." -3rd Doctor, "Terror of the Autons"


Mar 12, 2016, 02:05 pm #107 Last Edit: Mar 12, 2016, 02:11 pm by warmcanofcoke
For developing a prototype have you considered one of these:
X-Carve fully loaded 1000mm - 31" 0f carving area.

Wood Carver

Quote from: Theta Sigma on Jan 10, 2014, 06:28 am
I based the roundel cross section on the graphic that Teletran posted here:


Then I traced the graphic using lines and arcs in Google Sketchup to get a solid cross section.  Then I extruded the cross section into a circle, and here is the result.


Well, it's a start anyway.  I'm pretty proud of myself since I just started learning Google Sketchup tonight.

Here is a link to the sketchup file:  https://drive.google.com/file/d/0B9wuQYOPzaXceHFDM1FTMXhwdGc/edit?usp=sharing

Hopefully there is a way to convert this to AutoCAD, etc.  This doesn't solve the entire problem though, because for CNC machining you'd still have to define a tool path.

There may be a builders co-op near you where you might be able to use a similar device without having to buy one.
why doesn't the Guide mention them? - Oh, it's not very accurate.
Oh? - I'm researching the new edition.


Mar 12, 2016, 05:02 pm #108 Last Edit: Mar 12, 2016, 05:02 pm by galacticprobe
That thing is sort of like the "Compu-carve" my friend's wife bought him for a Christmas present a few years ago. If you can hook one of those (this thing or a Compu-carve) to your computer it should be able to turn out a nice wooden master to make a mould from.

"What's wrong with being childish?! I like being childish." -3rd Doctor, "Terror of the Autons"


Aug 08, 2016, 04:45 pm #109 Last Edit: Aug 08, 2016, 04:51 pm by propfix
Hello there!

It's been a little while since I checked in here, been busy doing exhibition work and Dalek wrestling (not at the same time, mind!).

How's it all going?


Theta Sigma

Lol, not much progress PropFix.  I modified my former profile to better match the castings, made up some lime putty to mix with the plaster, and then life got in the way.  There just never seems to be time.

I hope to find some time to work on it again soon.  It's on my mind daily.

"I just put 1.795372 & 2.204628 together." - 4th Doctor


Quote from: Theta Sigma on Aug 08, 2016, 06:44 pm
It's on my mind daily.

I know that feeling, particularly when there's a long list of projects to get on with!  ;)


Aug 09, 2016, 05:24 pm #112 Last Edit: Aug 09, 2016, 05:24 pm by galacticprobe
Hey, propfix! Nice to see you back again. And I was just about to ask Kev how things were going with this. (Looks like you beat me to the punch! ;D)

And I know how life gets in the way, sometimes more for some of us than others. So, brave heart, Kev! You'll find the time to get this done soon enough.

"What's wrong with being childish?! I like being childish." -3rd Doctor, "Terror of the Autons"