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MarkingMarking /TrammelGauge/Trammel

Mark perfect arcs, circles, parallel lines, and perpendicular lines with our walnut and brass homemade tool. Not only does it work with the precision you require, but the metal/ combina- tion makes for a great-looking tool as well.

DP-00141 ©Copyright Meredith Corporation 2001 Page 1 of 8 1/4" brass wing nut

1/4" brass flat washer BODY EXPLODED VIEW #6 x 5/8" F.H. brass

9/64" shank hole, countersunk 1 /16 x 2 x 4" 3 brass top plate /32" pilot hole 1/2" deep

3 /32" pilot hole 11 / 16" 1 /2" deep C 1/4" holes

7 1/16 x 1"-diameter /16" A and B are brass cover plate B glued together. 3/4" A 5 #6 x /8" F.H. brass 3/8" hole wood 5/8" deep

1/4" brass 9/16" threaded insert 1 3 /4" hole 1 /4" deep 1 for storing pivot pin /4" hole, countersunk on bottom side 9 /64" shank hole, 9 countersunk on /32" hole bottom side #6 x 5/8" F.H. 1/16 x 2 x 4" brass brass wood screws bottom plate 1/4 x 2" F.H. brass machine screw epoxied 3/4" to brass bottom plate 1/4" brass pivot pin 15/8" long (made from 1/4" brass flush rod)

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TM 3/8" hole 3 PENCIL HOLDER /4" EXPLODED VIEW 24" #6 x 5/8" F.H. 3/8" brass wood screws

E 1 1" /8" V-grooves 1/16" deep 3/4"

1/16 x 3/4 x 3" brass side plate

#6 x 5/8" F.H. 3 D /16" brass brass wood screws D wing nut

3/16" brass 10-24 x 11/4" F.H. flat washer brass machine screw epoxied to brass side plate 3/16" hole

3/16" hole, countersunk

Bill of Materials Finished Size Part Qty. T WL Matl. A body ‡" 2" 4" W 1 B body ‡" 2" 1Œ" W 1 C body Ø" 2" 1Œ" W 1 D pencil holder ˇ" ‡" 3" W 2 E bar ‹" ‡" 24" M 1 Materials Key: W–walnut, M– Supplies: „×2×12" brass bar, „ׇ×12" brass bar, (1) 10-24×1‹" flathead brass machine screw with flat washer and wing nut, (1) ‹" brass flush rod, (1) ‹×2" flathead brass machine screw with washer and wing nut, (17) #6×fl" flathead brass wood screws, (1) ‹" threaded brass insert.

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TM Note: Although the brass we used measures .064", it is often referred to as „"-thick brass. A See our source for a kit contain- ing all the necessary hardware in the Buying Guide at the end of the article.

Let’s start by building the trammel body 1 Cut the trammel body parts (A, B) to the sizes listed in the Bill of Materials from ‡" walnut. With one end and both edges flush, glue and the pieces togeth- er face-to-face. 2 Remove the clamp, and mark the centerpoint for the pivot-pin hole, where dimensioned on the Body Exploded View drawing. a ‹" hole 1‡" deep in the end, where dimensioned on the drawing. (We did this on our drill press, using a brad-point bit.) 3 Cut the remaining body piece (C) to size. Note that part C is „" thinner than the thickness of body part B. 4 From „×2×12" brass bar stock, crosscut two pieces 4" long each Make a slight depression on the inside face of the brass plates for the top and bottom body with a bit to remove the ridge. plates. You can cut the brass with 9 a fine-tooth blade on your band- To help eliminate bit wander, each ⁄64" hole. (We test-counter- , tablesaw, or scrollsaw. (We slide the drill bit as far as it will go sank holes in the remaining brass used the tablesaw with a 60-tooth into the . This supports the stock first, allowing us to accu- carbide-tipped blade, a zero-clear- bit more, allowing it to flex less. rately set the depth stop on our ance blade insert, and a miter When drilling through the brass, drill press. The screwheads need gauge fitted with a wooden the bit may create a small ridge on to seat flush in the countersunk extension. The zero-clearance what will be the surface that holes later.) insert supports the brass for mak- mates with the walnut. If the 8 Using double-faced tape, adhere ing a safer and cleaner cut.) ridge is not removed, it will pre- the bottom plate to the walnut or sand any burrs off the ends of vent the brass plates from mating body. Drill a „" guide hole the brass pieces. flush with the walnut body, creat- through the brass at the threaded- 5 Use a crafts to cut the Top ing a gap. To remove the ridge, insert location, giving you an and Bottom Plate full-size pat- mount a countersink bit into your accurate centerpoint for drilling terns. Using spray adhesive (we drill press, and very lightly the ›" hole into the wood later. used 3M spray mount #6065), machine the inside surface of 9 Separate the brass and wood, secure the paper patterns to the both pieces of brass plates to and drill a ›" hole fl" deep into brass. Carefully align the edges of remove the ridge. (As shown in the wood and a Ç" hole through the paper patterns with the brass. Photo A, above, we used a the brass for the threaded insert. 6 Fit your drill-press table with a Weldon countersink bit. It cuts 10 Install the ‹" brass threaded 9 . Chuck a ⁄64" bit into your clean with no vibration or burrs. insert in the ›" hole in the walnut drill press. Using the fence for See the listing in the Buying Guide (A). (To do this, we double-nutted 9 accurate alignment, drill the ⁄64" for our source.) a ‹" roundhead machine screw holes through both pieces of brass 7 Turn the brass pieces over (pat- and threaded the insert onto the where marked. tern side up), and countersink machine screw and against the

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TM B

Use the fence on your drill-press table to align the bit over the previously countersunk holes in the brass. nuts. Then, we used a and tion the fence to align the bit over Continue using the ‹" spacer a screwdriver to drive the insert the countersunk holes. (See the between parts B and C for sup- squarely into the hole. We used Buying Guide for our source of port. the radii to shape. the screwdriver to press the insert this bit.) Drill the pilot holes for (We used a ‹" skip-tooth blade.) downward and the wrench to the brass screws into the walnut 13 Drill a ‹" hole through the thread the insert into the hole. as shown in Photo B, above. To trammel body (A, C). Countersink Doing this is more accurate than help hold part C in place, use a ‹" one end of the hole, where shown trying to drive the insert in place spacer, as shown in the photo. on the Exploded View drawing, to with just a screwdriver.) 12 Drive #6×fl" brass flathead house the head end of a ‹×2" flat- 7 11 Chuck a self-centering ⁄64" Vix wood screws through the brass head brass machine screw. bit into your drill press, and posi- and into the trammel body. 14 Drum-sand the two radii. Then,

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TM lightly sand the edges and ends of 3 For hanging the completed end of the dowel with a screw. the trammel body. trammel, drill a ›" hole through Clamp the dowel in your work- the bar where shown. bench with the brass end up. Now, clean up the brass 4 Glue and clamp the pencil hold- File the edges of the cover plate and make it shine ers to the bar, aligning the V- flush with the edges of the dowel. 1 Using a round and a flat file (we grooves. See the Pencil Holder Then file and sand the round- used an 8" mill file and an 8" Exploded View for particulars. overs on the cover plate. round file), file a „" round-over 5 Cut two pieces of „ׇ" brass 3 Drill a Ï" pilot hole in the tram- along the edges of the brass top bar to 3" long to cover the outside mel body (B) for mounting the and bottom plates. face of the pencil holders. cover with a #6 screw. 2 Sand the exposed surfaces of Transfer the paper patterns, and 4 To form the pivot pin, cut a 1fl"- brass smooth. (To do this, we drill and countersink the holes long piece off the threaded end of used 180-, 220-, and 320-grit sand- like you did earlier with the brass a brass flush (toilet) rod. If the paper.) For an even shinier on the body. Note that the two threaded end is longer than ‡", appearance, sand with progres- screws on one brass plate are off- cut the threaded end to length, sively finer grits of . If set from those on the opposite then crosscut to 1‡" long. Chuck the screwheads protrude just plate. Secure the two pieces of the threaded end into your drill slightly, they can be sanded flush; brass to the pencil holders with press. Start the drill press and use if they protrude too much, #6 screws. a file to sharpen the end of the remove them and drill the coun- 6 Using your drillpress and a ‰" pivot pin. Sand the point until it tersinks deeper. bit, drill a hole through the brass- shines. Assemble the project in 3 Mix quick-set epoxy (5-minute covered pencil holders to house a the configuration shown.¿ epoxy), and epoxy the ‹×2" brass 10-24×1‹" machine screw. To machine screw in place. After the reduce the chance of chip-out, Buying Guide epoxy has cured, sand the bottom place a ‹"-thick spacer between Hardware kit. All the pieces list- plate again to remove any excess pencil holders when drilling the ed in the Supplies listing (brass epoxy and to smooth the head of hole. Countersink the hole. not cut to length). Catalog no. the screw flush with the brass bot- 7 With the spacer still in place, MGT2000, $20 ppd. For a Weldon tom plate. The ‹×2" brass screw bandsaw the radii on the pencil countersink bit, add $9.10. For a 7 and mating wing nut allow you to holders, and drum-sand each self-centering #5, ⁄64" Vix bit, add secure the trammel bar in the radius smooth. File and sand the $8.80. Puckett Electric Tools, 841 body later by simply tightening brass as before. Eleventh St., Des Moines, IA the wing nut slightly. 8 Epoxy the 10-24×1‹" brass 50309, or call 800/544-4189 or 4 Finish-sand the trammel body, machine screw in place, being 515/244-4189 for current prices and apply an oil finish to the careful not to get any epoxy on and to order. wood. Immediately wipe any fin- the exposed threaded end. Finish- ish off the brass. sand the pencil holder and bar. Produced by Marlen Kemmet Project Design: James R. Downing The pencil holder and Add the cover plate Illustrations: Kim Downing; Lorna Johnson trammel bar come next and pivot pin Graphic Design: Jamie Downing 1 Cut the pencil-holder pieces (D) 1 Transfer the 1"-diameter cover Photographs: Wm. Hopkins; Hetherington Photography to size. Tilt your tablesaw blade plate pattern to „" brass. Drill ©Copyright Meredith Corporation 2001 45° from center, and raise it „" and countersink the hole where above the surface of the saw table. marked. Cut the cover plate to Using a wooden extension on shape, cutting just outside the your miter gauge for support, cut marked line. The cover is used to a V- in each pencil holder cap the end of the ‹" storage hole (D), where shown on the Full-Size for the brass trammel pivot pin. Patterns and the Pencil Holder 2 Using double-faced tape, secure The purchase of these plans does Exploded View drawing. the cover plate to the end of a 1"- not transfer any copyright or other 2 Cut the trammel bar (E) to size. diameter dowel. Using the previ- ownership interest in the plans, the Check the fit of the bar into the ously drilled hole in the cover design, or the finished project to the body (A, B, C). The bar should plate as a guide, drill a pilot hole buyer. Buyer may neither reproduce slide smoothly, yet clamp securely into the dowel, and further the plans for sale nor offer for sale in the trammel body. secure the brass cover plate to the any copies of the finished project.

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TM FULL-SIZE PATTERNS

1 /16" brass bar 11 / 16" stock

1/4" hole, countersunk

1 1/4" hole /4" hole 17/8"

C

9/32" hole for threaded 9/64" shank holes, 4" insert countersunk 3/4" stock

7 B 9/64" shank holes, 1 /8" countersunk

2" 2" 2" TOP PLATE BOTTOM PLATE 1/4" hole 13/4" deep for pivot pin, drilled after gluing A and B

To ensure full-sized patterns are correct size, your printer should be set to print at 100% (not fit to page). Measure full- sized patterns to verify size.

fi 1" ‹‡

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TM FULL-SIZE PATTERNS

3"

3/4" stock 9/64" shank holes, countersunk 3/4" 3/16" hole

1/4" hole

top edges 1/16" brass bar SIDE PLATES 1/16" brass

3 5 /8" hole /8" deep 9/64" shank holes, 3/16" drilled on bottom side countersunk 3/16" hole, countersunk

4" 9/64" shank hole, countersunk

3" PIVOT-PIN HOLE A COVER PLATE

3 D /16" hole 3/4"

Locate E here SIDE VIEW 9/16"

D 5/16"

1/8" V-groove 1/16" deep 2" TOP VIEW 1/4" hole 13/4" deep for pivot pin, drilled after gluing A and B

To ensure full-sized patterns are correct size, your printer should be set to print at 100% (not fit to page). Measure full- sized patterns to verify size.

fi 1" ‹‡

SCALE

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TM