Automata workshop notes

Making Sid

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Here I document a few of the processes involved in making Sid Embraces Anarchism.
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    The first step is to think up the idea and sketch out design possibilities.

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    I buy beechwood in 8 foot long planks (2+meters), usually about 2 inches thick.
    Beech is an excellent wood for automata making as it has strength in all directions and has an even consistency and a fine grain.
    It is a hard wood though so I use lime for carving.

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    I cut the wood to approximate size on a bandsaw

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    I use a very precise Proton thicknesser to plane the wood to a tolerance of 0.1mm.

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    Some pieces are delicate and the wood is brittle across the grain so care has to be taken that it doesn’t split at this stage.

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    The thin parts are sandwiched together and they become much stronger in all directions.

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    Similarly for gear wheels I make 3 ply with the wood for extra strength.

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    I press the wood between wooden formers while the glue dries. Plastic film protects the formers from the polyurethane glue.

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    For smaller parts I make small pieces of ply from the beech.

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    Here the dog tails are being cut from 2 ply on the fretsaw.

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    I used to use a home built copy carver to get identical carving blanks. Now I have digitalised them and use a computer controlled router.

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    The parts are routed on both sides.

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    Front and back are glued together.

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    The parts are then carved and sanded.

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    I use gesso to produce a smooth surface.

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    The gesso is sanded between coats.

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    Acrylic paint and lacquer is then applied.

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    Other parts are finished with wax acrylic varnish, sanding between coats.

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    The brass parts are made on a Sherline lathe. Brass actuators are milled.

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    Mechanism parts being prepared

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    Counterweights for the cam followers. Made in 2 parts and glued together for strength.