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9.1.4 DOWELS
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Wood dowels come in every conceivable diameter, from about 1 16 to over 11.2 in. Wood dowels are 3 or 4 ft in length. Most dowels are made of high-quality hardwood, such as birch or ash. The dowel is always cut lengthwise with the grain to increase strength. Other than choosing the proper dimension, there are few considerations to keep in mind when buying dowels. You should, however, inspect the dowel to make sure it is straight. At the store, roll the dowel on the floor. It should lie flat and roll easily. Warpage is easy to spot. Dowels can be used either to make the frame of the robot or as supports and uprights.
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9.2 The Woodcutter s Art
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You ve cut a piece of wood in two before, haven t you Sure you have; everyone has. You don t need any special tools or techniques to cut wood for a robot platform. The basic shop cutting tools will suffice: a handsaw, a backsaw, a circular saw, a jigsaw (if the wood is thin enough for the blade), a table saw, a radial arm saw, or you name it. Whatever cutting tool you use, make sure the blade is the right one for the wood. For example, the combination blade that probably came with your power saw isn t the right choice for plywood and hardwood. Outfit the saw with a cutoff blade or a plywoodpaneling blade. Both have many more teeth per inch. Handsaws generally come in two versions: crosscut and ripsaw. You need the crosscut kind. If you are unfamiliar with the proper use of the tools that you are planning on using, you should go to your local library to look up books on woodworking, or find out when your local home improvement center is having classes on tool usage. Using the right tools and blades along with learning a few tips will make the work go much smoother and faster and result in a better finished product.
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9.4 FINISHING
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9.3 Cutting and Drilling
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You can use a hand or motor tools to cut and drill through wood. The choice isn t important and is really a personal one. The most critical parameter, however, is to make sure that you only use sharp cutting tools and drill bits. If your bits or saw teeth are dull, replace them or have them sharpened. Unless otherwise required, all cuts into wood are perpendicular (90 degrees) to its surface and, in most cases, the edges are also perpendicular to one another. To ensure that the cuts are at the proper angle, you should use either a miter box with your handsaw or a powered miter saw. These tools will help ensure that the cuts you make are at the correct angles and are as accurate as possible. It s important that you drill straight holes, or your robot will not assemble properly. If your drill press is large enough, you can use it to drill perfectly straight holes in plywood and other large stock. Otherwise, use a portable drill stand. These attach to the drill or work in a number of other ways to guarantee a hole perpendicular to the surface of the material. Before cutting or drilling, remember the carpenter s adage: Measure twice and cut once.
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You can easily shape wood using rasps and files. If the shaping you need to do is extensive like creating a circle in the middle of a large plank you may want to consider getting a handheld rotary cutter. Be careful if you are thinking about buying a simple rotary rasp for your drill; the bearings within a drill are designed for vertical loads, not side-to-side loads and by using a cutter with your drill, you may end up ruining it. After cutting the wood down into the desired shape, use increasingly finer grades of sandpaper followed by the painting process outlined in the following. The process outlined here will require just a few minutes to accomplish (over a few days, allowing for the paint to dry) and will allow you to create finished pieces of material (wood, metal, and plastic) that will have the functional benefits of:
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