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post #1 of 7 (permalink) Old 10-11-2012, 10:15 PM Thread Starter
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Just signed up and already have an urgent need for some help. My son is working on his Eagle Scout project which is a full size covered wagon. He has pretty much everything he needs and most of it is already for assembly. The tough part is the axles. These are about 3-1/2 x 4-1/2 and are 66" long, the very ends are tapered which then blends into an oval which then blends into the rectangular shape. Here's the tough part, the wood then fits into a cast iron part which pertty much follows the shape of the wood, that then fits into the hub of the wheel.

We don't need to be exact as the wagon will be used on rare occasions and then very short trips. My thoughts were to make up some sort of jig so I could use a router to cut the shape. Since the ends of the axles have both camber and toe-in, I am thinking of mounting the end not being cut onto a disc which would allow me to offset the taper for both camber and toe-in. Once one end is cut, they would be swapped and the process done again.

Does this sound feasible and has anyone ever heard or seen something like this? We have about a month to get this done so time is of the essence.

Thanks -
Greg
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post #2 of 7 (permalink) Old 10-11-2012, 11:00 PM
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Welcome to the forum.

Thank you for joining us, Greg.

That seems like a large project to complete in one month. Sounds like a job for a hand held spoke shave....That would be the way they used to do it.

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post #3 of 7 (permalink) Old 10-12-2012, 07:42 AM
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I agree with James, I would use a draw knife to shape it. Possibly cut off the bulk of the wood with jig saw or band saw first.
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post #4 of 7 (permalink) Old 10-13-2012, 09:45 AM Thread Starter
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Never used a spokeshave or drawknife, I figured if I could jig up my router, the repeatability would help eliminate variances. I'll be working on the jig and test pieces this week, let's hope for the best.
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post #5 of 7 (permalink) Old 10-14-2012, 06:21 PM
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Quote:
Originally Posted by Fibersport View Post
Never used a spokeshave or drawknife, I figured if I could jig up my router, the repeatability would help eliminate variances. I'll be working on the jig and test pieces this week, let's hope for the best.
Let us know how you get on, Greg.

Remember, this is a covered wagon, not a piece of fine furniture. No one will notice minor variances...

James
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post #6 of 7 (permalink) Old 11-04-2012, 09:38 PM Thread Starter
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Well it's been some time since I was here, I did manage to use the router to cut the tapers on the axles. There is also a shoulder that has a different center, I was able to rough that up as well. After both were cut, there was a fair amount of hand work to blend the two together, I ended up using a belt sander and a rasp which worked out well. The problem with doing this all by hand was the fact that the ends have to fit inside a cast iron end piece. Using my crude methods at least gave me an equal starting point for all four axle ends. Originally they would have mixed up some lead and linseed oil as a paste to fill in any voids, I'll be choosing fiberglass and resin. Still have to do some final fitting and cleanup but it'll work. I know it isn't furniture but the axle ends have to hold up a wagon that probably weighs in around 1000 pounds, it will be used also so I had to make sure it was a good as I was able to make it.
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post #7 of 7 (permalink) Old 11-04-2012, 09:50 PM
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Quote:
Originally Posted by Fibersport View Post
Well it's been some time since I was here, I did manage to use the router to cut the tapers on the axles. There is also a shoulder that has a different center, I was able to rough that up as well. After both were cut, there was a fair amount of hand work to blend the two together, I ended up using a belt sander and a rasp which worked out well. The problem with doing this all by hand was the fact that the ends have to fit inside a cast iron end piece. Using my crude methods at least gave me an equal starting point for all four axle ends. Originally they would have mixed up some lead and linseed oil as a paste to fill in any voids, I'll be choosing fiberglass and resin. Still have to do some final fitting and cleanup but it'll work. I know it isn't furniture but the axle ends have to hold up a wagon that probably weighs in around 1000 pounds, it will be used also so I had to make sure it was a good as I was able to make it.
Sounds like it's coming along
When you get a chance, we'd be interested in some pics

John Schaben

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