Screw & Bold Removers, Screw Extractors & Plugs

I hate to admit it, but even I mess up sometimes. A lot, actually. I use mostly brass screws, and they can strip easily if I use a cordless drill to drive them. Here are two options for saving the day. I own both. I NEED both.

The first is the ProGrabit Screw and Bolt Remover. I use this piece when I have stripped the head of a phillips head screw. This 3 piece kit contains everything you need to remove screws (sizes 4 thru 14) and small bolts.

To use it you, place the appropriate sized extraction tool in you drill in and run it in reverse to create a cavity in the screw or bolt head. You then flip the extraction tool in your drill so that the screw end can be inserted into the cavity. Again, running the drill in reverse, you back-out the screw or bolt.

The second option is the Cut-around Screw Extractor. I use this when I have snapped the screw head off of the screw completely.

You simply chuck this miniature hole saw into your drill, center it over your broken screw, then cut a plug out of the wood with the embedded broken screw in it.

When finished, you have a nice clean hole where your mistake once was. You can then plug the hole with standard size dowels or plugs cut with a tapered plug cutter. Cutting your own plugs will allow you to match the wood type, color and grain closely if you have some scraps from which to cut the plugs.

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Proxxon Micro Plunge Router for Miniature Work

I haven't tried a router this small (1/5 HP), but it sure does look like a good size for model and automaton making. This little router allows you to round-over, slot, counter bore, and remove stock from wood and other materials.

Some details on the router from Woodcraft:

* Depth adjustment of 0.008" increments
* Easy router bit changing with the shaft lock button
* Support columns are positioned so you can see as you cut
* Integrated suction device for connecting to a vacuum
* Parallel and circle jig made of die-cast aluminum
* Die-cast aluminum base and smooth gliding polycarbonate face
* Includes 6 pc. collet set
* Comes in plastic case

Here's more info on the Proxxon Micro Plunge Router

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CNC Shark Wood Routing System Available Online

Not long ago, I posted about the CNC Shark -- the new entry in the field of more affordable of computer controlled wood carving machines. I just noticed that Rockler Woodworking Supply is has started selling them online as the exclusive dealer. They are offering live demonstrations in stores too.


Here's what Rockler has to say about the CNC Shark:
Bring the speed and precision of computer-controlled machinery to your shop with this top value CNC system! With a table measuring 15-3/4" x 31-1/2" it's ideally suited for carvings and machining operations on a large variety of signs, doors and other small projects. It boasts impressive power, speed, accuracy, and ease of use. With its robust steel and high-density poly-ethylene construction, it can take accidental impacts that would normally damage or destroy an aluminum or MDF machine. Optional Clamping Table features two hold-down slots for securing work anywhere along the length of the table. Compatible with the Bosch Colt Palm Router. Includes VCarve Pro software interface — a $500 value. You supply a computer with USB port, a Bosch Colt router, and a table top (router and table top also available sold separately). You connect the USB cable to the controller box and the other end to your computer.

Visit a store near you for a live Demo.

CNC Shark Routing System at Rockler Woodworking Supply.

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FLEXCUT Starter Kit: 17 Carving Tools & Wood Box

Here's a post for the automata-makers and aspiring makers. Flexcut offers a set of carving tools in a starter kit. If you don't already own carving tools, this could be a great first set.

The kit comes with the most important carving tool of all -- the standard carving knife with a ergonomically designed handle. We're off to a good start.

In addition, the kit offers interchangeable carving tool tips of every conceivable shape that fit into a handle. This could be a bit a hassle if you need to switch blade types frequently. Flexcut wisely decided to give you TWO handles in this set. This is a simple and wise solution in my view. With the standard knife and two blades mounted in the palm handles, blade changing should be minimal.
The kit also comes with Flexcut's unique SlipStrop. A strop is a surface (often leather or leather-like) on to which you put a fine abrasive compound (also included). You run the tool over the strop to give it a fine, polished edge. What makes the SlipStrop so useful, is that it has a series of ridges shaped just like common carving tools. There are other ways to hone a carving tool, but this is very convenient. I have used one for years.

Finally, keeping track of all those interchangeable blades could be a burden, but the kit is packed in a nice wood box, which should protect your set and keep it organized.

Get a full list of the tools included in the FLEXCUT Starter Kit.

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CNC Shark Routing System - Autonomous Carver

I posted a while back about the CarveWright automated carving system. A new model of Computer Numerically Controlled (CNC) router has entered the market at a similar price point -- well below more established, larger machines. The new one is called the CNC Shark Routing System.


This CNC machine is designed for routing wood, engraving plastics, and even etching or cutting tile.

Like the CarveWright, the CNC Shark is a fairly small, portable machine. Unlike the CarveWright which uses a media card to transfer information from your computer to the Router table, with the CNC Shark, you connect the USB cable from your computer directly to the controller box.

Another difference is that the CNC Shark uses a conventional palm router mounted to it to do the cutting. The CarveWright routing system uses a specialized flexible shaft attached to an on-board motor. The CNC Shark's system allows you to use a router you may already own (like the Bosch Colt Palm Router), or may choose to use on its own. Since this is the part that will get the most wear and tear, I think this is a brilliant approach. The palm router can be fixed or replaced. Bits for the palm routers are easy to find too.

Unlike the CarveWright, which uses its own proprietary software, the CNC Shark can be used with a range of established CNC programs used in the industry. There may be a learning curve here, but it's probably worth it for greater control.

The last important difference that I can see is that this machine moves in all three axes of motion (X, Y, and Z). The CarveWright moves side to side and up and down. For lateral motion, the CarveWright uses a friction belt (i.e. sandpaper belts) to move the workpiece itself. This seems like a potential area for slippage which could ruin a carving. The CNC Shark never moves the work piece -- only the cutter moves, ensuring that registration is on target.

From the product literature:
The CNC Shark is the best value for a complete CNC system. This impressive has power, speed, accuracy, and ease of use. We also have a technical support system to help you with any questions regarding the and any of its software. CNC Shark has a high quality design and its parts have been CNC'd to ensure its highest accuracy. The Shark's construction of steel, aluminum and high-density polyethylene make it robust, and it can take accidental impacts that would normally damage or destroy other machines.

The CNC Shark is offered through the Rockler stores in the lower 48 United States. Take a look!

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Steps to Fix Your Broken Portable Power Tools

When a power tool stops working, a broken electrical part is the likely culprit. Don't throw that tool away! Fix it! Better yet, pull one out of someone else's trash and bring it back to life.

Though there is a huge variety of electric power tools, the basic electrical components -- cords, switches and brushes -- are similar regardless of the tool's purpose or manufacturer.

From the article:
"(The) procedure for tracing problems begins with testing and examining wires, then switches and finally brushes. The only special tool you will need is a multi-tester, available from an electronics shop for about $25. With it, a host of problems can be traced right to the source. Many electrical components on power tools can be replaced for $20 or less if you do the repair work yourself."

Here's a link to the article, Basic Repairs for Portable Power Tools

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Easily & Safely Cut Small Parts on the Table Saw

In previous posts, I mentioned the value of having miniature power tools for small scale projects. I find them to be less intimidating and more appropriately scaled for small scale work. They are also great space-savers if your shop space is limited.

But what about using traditional woodworking tools? You may already these tools or want to buy them to work on full-scale home and woodworking projects. You can still cut small pieces on full size tools with some proper planning and helpful jigs.

One such jig is the one shown here. This simple sled allows you to use a full size table saw to rip very thin pieces of stock safely, easily, and uniformly.

The sled is simply a piece of melamine that been ripped to a 10-in. width. After ripping the sled to width, a small block is glued on it to act as a hook to hold and push the material being cut.

Take a look a the full article on the Small Parts Sled from the folks at Woodworkers' Journal. [Thanks Charles!]

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Proxxon Rotary Tool & Accessories

I own some Proxxon tools and I own several rotary tools, but I don't actually own a Proxxon rotary tool.

OK..that said, I love the Proxxon tools I do own. Woodcraft is sellng the Proxxon rotory tool at a close-out price right now (about $73). The specifications do sound impressive (see below).

Personally, I am very interested in that Universal Holder (D) for use with a flex shaft (sold seperately). That looks handy, indeed.

From Woodcraft's Site:
Great for detail cutting, grinding and sanding, the German-made Proxxon has a top speed of 20,000 RPM, continuously variable down to 5,000 RPM. Electronic full wave speed control gives almost constant torque, even at low speeds, easing micro drilling. The spindle rides in precision ball bearings, and has a lock button for changing bits. The Proxxon gets its power from a quiet, specially balanced permanent magnet motor. Our own testing showed superior low-end torque and far less vibration than the most popular rotary tool on the market.

Check out all the details of Proxxon Rotary Tool & Accessories over at Woodcraft.com.

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Proxxon Micro Shaper

Often, full size woodworking tools are just too big or too powerful for working on small scale projects such as an automaton. Fortunately, companies such as Proxxon make power woodworking tools for small scale projects. I've posted in the past about the Proxxon Miniature Tables saw and the Proxxon Miniature Miter Saw -- both of which I own. Here is The Proxxon Micro Shaper, a small router table that takes 1/8" bits. (I don't own this yet, but I will one day.)

From the Product Literature:
This miniature router table is the perfect sized machine for small-scale routing and trimming applications. Ideal for model building such as railroads, airplanes, doll houses and more! Features powerful 115V, 60Hz, 1/8 HP motor.

Check out the Proxxon Micro Shaper at Rockler Woodworking.

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Miniature Workbench to Work on Small Parts

Working on miniatures or any small part can present a unique set of challenges. Sometimes the job requires small tools. Other times, you just need a way to hold the piece so you can work on it in comfort and safety.

Here is a solution that I wish I had thought of years ago.

This little bench is 13-1/2" high with a 1" x 3-1/2 x 8" top. You can't really see them in the photo, but the top has a row of nine 1/8" x 5/16" miniature dog holes. The whole thing can be clamped in a vise or to the surface of a larger bench. The third option, shown here, is to sit on the splayed wings that form the base. Two bolts in the top act as screws for the wooden end vise.

Read more about this and more elaborate arrangements in this article on miniature workbenches.

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Video of CarveWright Wood Carver in Action

Here is a video of the nifty CarveWright computerized woodcarving system in action. It's a woodworking robot.

CNC routers are nothing new. But, as I mentioned in a previous post, this system's price doesn't make it totally out-of-the-question for the personal wood shop.

In this video you get to see how the machine is set up and used, how bits are changed, and the basic CAD-like software it comes with. It sounds a bit noisy, but hey...it is a power router after all!

Here is more detailed info on the CarveWright at Woodcraft.com.

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CarveWright CNC Woodcarving Machine

I take pride in the hand-crafting that goes into making each Dug North Automaton. Still, there is a tool addict side of me that cannot help but dream about the possibilities of a machine like this one: The CarveWright CNC Woodcarving Machine.

While less robust than full-fledged CNC router table, the price of this machine is so much less, it is in a class of its own. I won't go into the technical details of this automatic wood carving machine here...they are too numerous.

Just consider this for a moment: automata building more automata. Wow.

Check out the CarveWright Woodworking System.

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Make A Lathe Out Of Your Drill Press

Some time ago, I posted about an accessory to convert your power drill into a small lathe.

I was visiting the toolmonger site the other day when I saw this tool which looks like a far more robust option if you already own (or plan to own) a drill press.

This accessory sold by Grizzly allows you to turn a multi-speed drill press into a vertically oriented lathe. What a great idea! It looks like it would be fairly easy to setup and change from drill press mode to lathe mode.

A 12" tool rest allows a maximum work piece length of 24" -- if you reverse the piece to work on the other end. The set includes a base plate with live center, 12" tool rest, mounting bolts, mini screw center, and spur center. It fits all drill presses with a through hole in the table. All of this for about $20. Wow.

Take a look at this Lathe Attachment for Drill Press.

You may want to take look at this highly-rated set of lathe chisels to complete your new setup.

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PROXXON Mini Miter Saw Model

I own two Proxxon miniature power tools and they are both amazing. Not "amazing for their size" -- just plain amazing.

The mini miter saw is a great addition to any model-maker's or automata-maker's tool collection (or any work area where space is tight). This miter saw is great for cutting 90 degree and 45 degree cuts in a variety of materials. There are detents every 15 degrees for cutting a range of angles.

The saw has a really clever integrated clamp to hold the material and ensure that your cut stays on the mark. There is also a built-in stop to help you cut a bunch of pieces to the same length. Nice.

As with PROXXON Mini Table Saw, these miniaturized tools are clearly not toys; they are solid and exceed one's expectations in terms of performance. Seriously, the mini table saw can make a clean cut in 3/4" hardwood and it's barely bigger than a toaster.

The truly handy thing about owning the miter saw AND the table saw is that they use the same blades. You can get a variety of blades for slitting, cutting wood, and cutting metals. I have found the miter saw mounted with an abrasive blade for non-ferrous metals to be a great way to cut brass rod and bars to length.

Check out all the details on the PROXXON Mini Miter Saw Model and the PROXXON Mini Table Saw

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Work Sharp - PowerTool Sharpening System

I am always looking for the next new type of sharpening tool. Let me introduce you to the Work Sharp 3000.

The Work Sharp employs a spinning glass wheel on to which you have adhered an abrasive sheet. The "see-through" wheel allows you to look down to see what you are sharpening.

The sharpening port enables sharpening of 20, 25, 30, and 35 degree angle chisels and plane irons up to 2" wide without he use of a jig.

The unit is cooled with forced air and a heat sink allowing you to removal metal without affecting the steel's temper. This means you won't ruin your tools.

The Work Sharp 3000 comes with a 2 year manufacturer's warranty, 2 tempered float glass wheels, a see-through slotted wheel, top tool rest, a crepe stick, and PSA abrasive kit.

Head over to Woodcraft.com to check out the Work Sharp 3000

I see that Amazon also carries the Work Sharp 3000.

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Spyderco Sharpening Ceramic Stones

As some of you know, I am a advocate for sharp woodworking tools. Traditionally, fine woodworkers have used water stones. Other options include oil stones, abrasive papers, and more recently, diamond impregnated plates.

Water stones are messy (as they must be stored in water, used wet, and occasionally flattened). Likewise, oil stones require honing oil which can be a bother. Abrasive papers wear out (meaning there is a large hidden cost). Diamond stones are convenient because they only require a bit of water as lubricant and don't need flattening. They are, however, somewhat expensive.

Spyderco is now offering ceramic sharpening stones. These new ceramic stones seem to have everything going for them: no oil, no water, no wet storage, no flattening, no replacing paper. They require only the occasional cleaning with an abrasive kitchen cleaner (Comet, or the like). They are fairly affordable to boot!

Note that Spyderco has the traditional flat stones (right) for sharpening chisels, planes, jointer blades, and knives. In addition, they are have a set of specially shaped stones (left) for sharpening odd shaped carving tools.

Check out the new Spyderco Ceramic Sharpening Stones.

Here's a video on the product courtesy of Woodcraft Woodworking Supply.

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Proxxon Precision Drill/Grinder

Proxxon Precision Drill/Grinder
Precision drill/grinder is ideal for milling, drilling, grinding, polishing, brushing, cleaning, deburring, sawing, carving, engraving, rust removal and more!

Proxxon Router Base Attachment
If you make small boxes, frames or furniture, this router base attachment is the right tool for you! Great for routing slots, notches, grooves, edges and profiles with or without the fence or circle attachment (both included).

Check out the Proxxon Precision Drill/Grinder

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Convert Dremel into Miniature Milling Machine

The New ACRA Mill Plus was designed with the serious model maker in mind. It is so easy to use, even the beginner will find it a great asset. You can do the most simple modeling tasks (sanding, grinding, polishing, etc.) and the most precise jobs -- working to within .001" if needed. All of this, by mounting a Dremel Rotary tool, or any Dremel-style rotary tool.

Though I have already bought Mini Milling Machine and a 7" x 12" Mini Metal Lathe, this tool little beauty is almost too tempting to pass up. Let's see how long I last before I break down and buy one.

Check out the ACRA Mill Plus.

As usual, this gem comes to me by way of Make Magazine's extraordinary blog.

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Diamond Sharpening System for $50!

Diamond Tri-Hone Sharpening System

This is a great product at full price ($70), but a GREAT deal at Rockler's current sale price of $50. Diamond stones are effective, easy to care for, and last a long time. I've used a Smith Tri-Hone for years (pre-diamond version) and have always found the system to be convenient. This 3-stone sharpening system features coarse and fine diamond stones and natural Arkansas stone for final finishing. You just flip the center element around to put the grit of your choice facing up. Notice also, that the diamond face includes a micro-tool sharpening pad for small tools (such as carving tools). The set comes with a helpful little a helpful little angle guide and sharpening instructions. Check out the Diamond Tri-Hone Sharpening System

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File with a Scroll Saw - Scroll Saw Sanding Files

I have been using small sanding belts in my scroll saw for some time. They are sold under the brand name of Scroll Sanders. They are great. I use my scroll saw for sanding more than I use it for cutting!

Here is another good idea that I am ready to try: Scroll Saw Sanding Files.

Mount these little beauties into your scroll saw to turn it into a power filing machine. The product literature says that the silicon carbide abrasive is aggressive enough to cut as well as sand in most materials.

They can also be mounted into pin vises, craft knife handles, and mini hack saw handles, so I am sure to find a use for them. I'm going to order some today and I'll let you know if I like them.

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Engineer's Sqaure and Caliper Set

Woodcraft is selling a set of three engineer's squares (which are much more precise than your average woodworking square), along with a nice little brass caliper. The set comes in wooden case for storage.

For $35, I consider this to be a pretty good deal.

Check out these Engineer's Squares at Woodcraft.com

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Grizzly Drill-Powered Hobby Lathe

Here is an interesting tool that converts your 3/8" power drill into a miniature wood lathe.

The details on this tool are limited, but impressive for the price. It can accommodate work of up to 24 inches and 6 inches in diameter. That's pretty big, really.

At about $46.00, this could be a handy tool -- especially if space is limited or you just want to try out a lathe of your own on the cheap.

The funny thing is that a well-rated set of lathe chiselsmight cost you more than the lathe itself!

Check out the Grizzly H2669 Hobby Lathe

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Useful Tools - Reader Submissions

A dedicated Automata-enthusist and reader of The Automata / Automaton Blog wrote to me with a list of tools that he has found useful for making automata.

I've enumerated his list of tools, and provided several sources and variants for each.

1. Small Drill bit sets
   
• 20 Piece Wire Gauge Drill Set and 3-Jaw Micro Chuck from Rockler
  
• 20 piece drill set sizes #80 to #61 from Lee Valley
• 20 Piece High Speed Steel Jobber Drill Set in Steel Case,#61-#80 Numbered Drills from Amazon.com
• Mini Chuck and Wire Drills from Woodcraft
2. Wire Bender
• WIRE BENDING JIG, ALUM
  
• Wire bending jig from Lee Valley
• Strip and wire bending jig from Micro-Mark
  
3. Ultra-Thin Razor Saw
• Razor saws from Lee Valley
• Model-makers Razor Saw from Woodcraft
• Mini Saw and mitre box from Rockler
  

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How to Sharpen or Fix Broken Drill Bits

Over time, drill bits become dull and cease to cut effectively. Sharpening dull bits can improve the quality of your work, put less strain on your tools, and generally make drilling safer (since you can let the bit do the cutting, rather than applying force that can cause the bit to break). Sometimes, drill bits do break. You don't necessarily need to throw it out!

One option is to buy a Drill Doctor. These range from $50 for your Basic Drill Doctorto their $150 Professional Drill Bit Sharpener.

Here's an article on How to Sharpen Twist Drill Bits.

The article shows you how to freehand-sharpen a twist drill bits using a grinding wheel. While it's not too difficult, there are several important things one must know and do. In addition to learning the correct angles, the article explains the three distinct motions one must use while holding the bit against the grinding wheel.

1 - Move the bit to the left (grinding on the left edge only)
2 - Rotate the bit in clockwise rotation
3 - Move the bit downward

Read the full article on Resharpening drill bits, courtesy of Woodcraft woodworking stores.

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Win a Laser Cutter from Instructables

Instructables is giving away a BrightStar LG3040 laser cutter package worth over $6000!

To enter the contest, here's what you need to do:

1. Publish an awesome Instructable on any subject anytime between April 15th and Sunday June 17th 11:59 PM PDT and add it to the Laser Cutter contest group. They will judge the projects with help from Squid Labs and past winners, while taking into account each Instructable's rating and number of pageviews as another "judge."

Entries do not have to involve lasers; any Instructable is eligible. The focus is on sharing what you're passionate about.

2. Five finalists will be selected and announced around Friday June 22nd. Each of the five finalists will need to submit a proposal telling what they would do with the laser cutter.

Check out all the details of Instructables Laser Cutter Contest

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Scroll Saw Joinery

Scroll saws are great for cutting curves and complex shapes. Did you know you can also use the scroll saw for joinery?

Here's a really interesting that article shows you how to cut a variety of interesting joints on the scroll saw.

Read the article: Scroll Saw Joinery originally published in Scroll Saw Workshop magazine

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Miniature Table Saw - Amazing!

I recently bought some new tools. The first thing on my list was a miniature table saw. My full-sized Craftsman is going strong after forty or more years, but it often seems like too big of a saw for the pieces I cut for automata.

I did some research and bought the Micro-Mark version of what you see here (Proxxon). I am 99% sure that they are made by the same company for every detail is the same except that mine is black.

Simply put, these little table saws are amazing. The saw is very strong and precise. The saw is quite capable of cutting hardwoods and the speed can be adjusted for the material.

There are a variety of blades available including a carbide tipped, diamond, abrasive disks, and fine toothed slitting blades. There are also many fine accessories (rip fences, feather boards, cross-cut tables, tapering jigs) available. I comes with a basic rip fence and mitre slider.

Buying this saw had an added advantage...I was able to free up space by moving my full-size saw out of my primary work area because I need less often.

If you need a good saw, don't have a lot of space, or work with small pieces I think these miniature table saws are a great choice. I LOVE mine.

Check out all the the details on this Miniature Table Saw.

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