Merry Christmas 2009

Merry Christmas Everybody.
I recently added 3-d software to my CNC. My first projects were props for the Christmas musical at church last week. I know this is a hot rod site, but I just had to show off the capabilities of this new software. I had a blast putting these together.
First were the angel wings. complete with an aluminum harness made with the E-wheel I built last fall, along with some help from the bead roller & press.

http://img.photobucket.com/albums/v2...Finishpass.jpg

http://img.photobucket.com/albums/v2...gsFinished.jpg

http://img.photobucket.com/albums/v2...ngHarness1.jpg

http://img.photobucket.com/albums/v2...ngharness2.jpg

Harness welded, bead rolled edge to stiffen up the .080 aluminum. Bead rolled tabs to be embedded in the polystyrene wings to mount them to the harness.

http://img.photobucket.com/albums/v2...ngHarness3.jpg

After a test fit on the guy playing the angel, the harness didn't want to stay in place with the straps only, so I added a couple shoulder braces made from .080 aluminum. A bead down the center of the straps made them strong enough to hold the wings up, but were still pliable enough to bend to fit his shoulders.

http://img.photobucket.com/albums/v2.../Wingsdone.jpg

They stayed in place for all 4 performances. ;)

http://img.photobucket.com/albums/v2...NGSONSTAGE.jpg

Those are some very cool angel wings!

Thanks Roger. But wait...there's more......

Next was the sign for the entrance to the parking lot.

I made this out of Styrofoam. Pretty flimsy stuff for outside use, so I laminated it to a sheet of OSB to stiffen it up, then cut it on the CNC.

http://img.photobucket.com/albums/v2...nceSignFCC.jpg

Cut the main lettering & dove out separately to be applied after the main sign was painted.

http://img.photobucket.com/albums/v2...28/DoveFCC.jpg

http://img.photobucket.com/albums/v2...CCFinished.jpg

Installed

http://img.photobucket.com/albums/v2...nstalled-1.jpg

Next was a 16'x4'x12'' "earth" to cover the center stage steps.

http://img.photobucket.com/albums/v2...ldAssembly.jpg

http://img.photobucket.com/albums/v2...dyforpaint.jpg

http://img.photobucket.com/albums/v2.../EarthDone.jpg

http://img.photobucket.com/albums/v2...hinstalled.jpg

The last prop was a life sized camel. This was a challenge especially since I just got the software a week before Thanksgiving. It took about 200 hours. About 1/2 of that was labor & 1/2 machine time on the CNC.

I started out by taking a pic. of a ceramic camel from a nativity scene I did about 20 years ago. I took a left & right side photo & converted them to vector art. I then converted the vector art to this 3-d image. (this being the right side).
http://img.photobucket.com/albums/v2...lrightside.jpg

Being 7' tall x7' long x 32'' wide I had to slice the model into 2" slices so I could cut them out of 2" polystyrene foam. (the pink stuff from Menards).

http://img.photobucket.com/albums/v2...elroughcut.jpg

Built an armature to hold the camel together.

http://img.photobucket.com/albums/v2...28/Armture.jpg

Getting ready to join the left & right sides together.

http://img.photobucket.com/albums/v2...ureembeded.jpg

All assembled and smoothed out with water putty. There was a fair amount out relief sculpting that had to be done as my CNC does not have a 4th axis.

http://img.photobucket.com/albums/v2...amel12-101.jpg

In primer & ready for some color.

http://img.photobucket.com/albums/v2...PaintReady.jpg

Left side done

http://img.photobucket.com/albums/v2...tedCamelLt.jpg

Right Side Done.

http://img.photobucket.com/albums/v2...hedCamelRt.jpg

Loaded up and ready for the trip to the church.

http://img.photobucket.com/albums/v2...adedCamel1.jpg

http://img.photobucket.com/albums/v2...28/wisemen.jpg

On display in the church foyer.

http://img.photobucket.com/albums/v2...inthefoyer.jpg

That's what I've been doing for Christmas this year.

Wow you've created some amazing stuff. You could make a living doing that kind of stuff in Hollywood! Your church must feel very fortunate to have you as a member. I bet you were cleaning up foam dust for days!

Wow, who would have thought you could use a CNC machine as a ministry tool? Awesome stuff, Pro. Blessings to you and yours; kudos on using your talent for the Lord's work.

Being in the Tool and Die buisness and seeing that profile on a 3 axis machine is really impressive.What is the CNC table size?

I am sure a crown is in store for you, to show that kind of dedication.

"Merry Christmas"

Thanks everybody. Don, the table is a 4'x8'.

Wow Gary, with talent like that, you ought to go into the sign makin' business!

Merry Christmas and God bless your clan.

Quote:

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Originally Posted by falconvan

Wow, who would have thought you could use a CNC machine as a ministry tool? Awesome stuff, Pro. Blessings to you and yours; kudos on using your talent for the Lord's work.

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Ill second that..That is amazing work,pro,totally amazing..:cool:
I hope you and your family have a very good Christmas,from us and our church,Cornerstone Baptist in New Plymouth..
And of course,same goes for everyone on here...Robin and Lynda..
Incidentally,its 7.05pm,Christmas Day,havent eaten since midday,havent needed to...**)

Thanks again. I couldn't have done it without my helper.

http://img.photobucket.com/albums/v2...hanCamelMe.jpg
Grandson Ethan 20 months.