Carousel Build

[DanoNJ]

New for 2013, I started the build on a carousel. Unit will be just under 5' wide and about 5' high. I basing the build on plans I purchased from Winfield and will be completing some modifications.

First step was to make the base which is simply some 2x6s. I made some wooden gears (a bit of a pain to cut out and make fit well). The main gear sits on a lazy susan.

 

[DanoNJ]

Of course I'm using a wiper motor for power running at 5vdc. These pictures show the motor housing and main gear on the base frame.

 

[DanoNJ]

Floor sides cut.
And the floor joists.

 

[DanoNJ]

Center colum. The stringers have to be cut on an angle. The colum will be held in place by L's which have to be set into the strigers.
Picture shows the inside of the colum before the skin is applied and the finished product.

 

[DanoNJ]

Short video of the gears - test mode.

http://www.youtube.com/watch?v=61iH2a1w45k&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=3

 

[DanoNJ]

another short video of the floor on the base.

http://www.youtube.com/watch?v=DQOoYOiZb08&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=2

 

[DanoNJ]

Here is a picture of the base w/ gears. The center post adds some stability to the upper part of the unit. It does not get attached to anything, the colum slides over top.

The other picture is the top. From each of those will be attached the roof rafters.

 

[DanoNJ]

I made the decison to go with some 3/4" box steel for the roof suports to help with the possible sag / warp issue. What I did was cut to length and drilled and tapped one end. This end will be attached to the center support board. This makes up the bottom section of the roof structure.

 

[DanoNJ]

On to the rafters. You'll get a better understand of the topper picture posted earlier now.
And a dry fit of the parts.

 

[mpurser]

sorry all the links to videos are bad you tube says video does not exist

 

[DanoNJ]

The end of the roof rafter are also beveled to accept the side panels. Top top of the side panels are beveled to accept the roof.

 

[DanoNJ]

Roof panel

 

[DanoNJ]

I not only want the unit to spin, but I wanted some (there will be six) of the characters to go up and down, just like a real carousel. To make this happen, I made a circle of 1/2" ply around the base of the unit. In order to bend the ply, I had to score the underside multiple times. This way the ply would bend without cracking. Now, I can cut some curve in there.

 

[DanoNJ]

So, how will these characters move? Each of the isx will be attached to a length of 3/4" PVC pipe that runs from the floor to the roof. Three of these, the ones moving, have a length of 1/2" box tube inside. Attached to the box steel is a wheel from a roller skate. The wheel is attached to the box with a piece of metal welded on.

a picture shot up underneath to give an idea on how the wheel will 'ride' on the plywood.

 

[DanoNJ]

The video shows the unit spining clockwise. I have since changed the direction, but you get the idea.....
http://www.youtube.com/watch?v=_4HysZyMLUE&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=1

 

[aaron1]

Amazing. Can't wait to see the characters you're adding.

 

[jklingert]

Amazing job Dano!! I can't wait to see the finished carousel.

 

[DanoNJ]

More build.

 

[Jeff Millard]

Dan,

That's beautiful. I was wondering why the wipers stopped working in my F-150...

Jeff

 

[DanoNJ]

Dan,

That's beautiful. I was wondering why the wipers stopped working in my F-150...

Jeff

Did you really need to wonder?? Thanks, Jeff.