How to make your own pulleys and belts for small mechanical projects

The latest installment of my quarterly column, Dug's Automata Tips, Techniques and Tricks is now live on the Cabaret Mechanical Theatre site. To celebrate two full years of Tips, we'll have some fun with pulleys and belts. I show you exactly how to make small wooden pulleys for automata and other small mechanical projects, drawing on my previous article on How to Cut Wooden Circles for Your Automata Projects. I also show you what an O-Ring Splicing Kit looks like and how you can use one to create belts of any size to go with your pulleys. This should be all the information you need to start using pulleys and belts in your projects right away. I hope that it proves useful to readers.

Here is where you can read Dug’s Automata Tips, Techniques and Tricks No. 9 on Making Pulleys and Belts for Automata Projects.

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If you were to have just one book on making Automata and Mechanical Toys, this might be the one to have

The name of this book says it all for indeed, it deals with Automata and Mechanical Toys, and it does it well. The book covers the history of automata, contemporary makers, and the construction techniques you will need to start making them yourself.

What will you find in Automata and Mechanical Toys? The chapters of the book are as follows:

1. A Brief History of Automata and Mechanical Toys
2. The Origins of Contemporary Automata
3. Tools and Materials
4. Techniques
5. Making Automaton Mechanisms
6. Theme Projects
7. Design
8. Painting and Finishing

That's pretty much everything you could ask for in book on automata.

The chapter on the history of automata is among the best short treatments of the topic, dealing with the clockwork examples from history and placing the contemporary form that is the subject of the book in context.

Each chapter is interspersed with profiles of leading automata makers, showcasing their work with many pictures and a page or two of information about the artist. The artists featured are among the best known automaton makers in the United Kingdom. You'll see profiles of Lucy Casson, Ron Fuller, John Grayson, Neil Hardy, Andy Hazell, Tim Hunkin, John Maltby, Tony Mann, Peter Markey, Ian McKay, Frank Nelson, Rodney Peppe, Robert Race, Martin Smith, Paul Spooner, Melanie Tomlinson, Douglas Wilson, Kristy Wyatt Smith, Vicki Wood, and Jan Zalud.

The photographs of automata in this book are outstanding. Printed in full color on glossy paper, you can really get a sense for the devices, their construction, and the finishes that add that artistic touch.

The section on tool and materials is quite good and provides some translation of terms for speakers of American English (e.g. a "pillar drill" is what we call a "drill press"). The sections that cover construction techniques are clear and informative. In addition, there are printed patterns for pin-wheels, ratchets, cams, and splined gears. If you are just starting out, these patterns are invaluable.

A particularly cool thing about this book is the section on the automaton mechanism test platform. The reader is given complete instructions for making commonly used mechanical components. These can then be fitted to the test platform in order to see them in action. The final product is a bit like an interactive display at a science museum. The construction and use of this platform would make a great classroom aid or science fair project.

You won't find plans for any complete automata projects in this book. For that, you'll have to turn to one of the author's other books, Making Mechanical Toys, which is a great companion volume. What you will find are instructions for how to make the components you'll need to make an automaton of your own: ratchets, pinwheels, gears, linkages, cams, cranks, a Geneva wheel, and so on. This is really useful stuff.

Somewhere between a how-to book and a coffee table treatment of the art form itself, the book may frustrate those who want to focus on just one thing or the other. But, if you love automata, want see examples by well known automata artists, and want to learn more about how to make these wonderful devices, then this book is a must-have. If you were to own just one book on automata making, this is probably the one to have.

Click here to learn more about Automata and Mechanical Toys

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Hand-cranked mini ball track soon to be available in kit form

The folks over at BustedBricks.com offer hobby supplies and laser cutting services. To this useful list, they will soon be adding the nifty little rolling ball sculpture shown in the video as a kit! The video shows a test version of the kit. The final version will have a an easy-to-assemble laser cut plywood track, which does not require soldering skills or equipment. I adore the laser cut gears!

The kits will be available on Friday of this week at www.bustedbricks.com. I'm thinking these would make great holiday gifts. In the meantime, I recommend you check out the Stirling Engine Kits they currently offer!

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Cram Guy - a kinetic sculpture by Seth Goldstein

Take look at this video of a wildly inventive kinetic sculpture by Seth Goldstein! The piece depicts a student studying for an exam who falls asleep at his desk and starts to dream. I love the diversity of objects used in this piece.

[ Thanks Brad! ]

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Model car integrated into wall mounted kinetic gear train sculpture

Check out this new wall mounted kinetic sculpture by Brett Dickens. We're not unfamiliar with the his wooden gear sculptures, but this one has an interesting addition: a 1:25 scale model of a 1948 Ford Woody Wagon. The Woody is situated above a ramp, which is set into motion by the gear train. Once the ramp meets the wheels, the car goes for a ride.

See more kinetic sculpture by Brett Dickins on his YouTube channel.

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Fluttershy's Bird Choir - a new My Little Pony themed wood automaton

Did you see the My Little Pony wood automaton I posted back in June? Here is the another by the same artist. It is an unexpected sub-genre that is wonderfully incongruous. Whether you agree or not, just look at the craftsmanship!

From the YouTube description:

This third piece in my pony automaton series proved to be the most difficult to design and make by far as I wanted to match Fluttershy's grandiose reputation. Other than the typical moving parts, her bird choir actually sings! The characters, box (stand) and fence are carved out of Philippine mahogany as are the cams, bellows and slide whistle. The gear train and lever arms are made of Narra hardwood. Fluttershy stands at 6"; with the entire display it measures 10 1/4" high, 8 1/2" long, and 4" wide. The entire piece took me a staggering 182 hours to complete.

This very complex and well made automaton is currently for sale on ebay. Check out the pictures and description or just go ahead and buy this one-of-a-kind creation. Here is the eBaby listing for the Fluttershy's Bird Choir wood automaton.

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An in depth look at a steam-powered dancing man by toymaker Ron Fuller

I highly recommend spending 10 minutes with automaton and toy making legend Ron Fuller. In this video Fuller explains the design and construction of a dancing figure that is powered by the steam produced from a small boiler heated with an alcohol lamp. Once the boiler reaches temperature, we get to see the figure dance...and boy, does it dance! There may or may not be a fun little surprise toward the end of the video, but I refuse to say.

Fuller also shows some more traditional examples of dancing figures or "limberjacks" as they are sometimes called. He notes that the addition of a side-to-side motion really helps to improve the dancers motion. I think you'll agree. I love how one arm of his dancing figure is particularly animated, while the other moves just a little. This adds a lot of character to the motion.

Here are a few fun facts you might not know about Ron Fuller.

[ Thanks Paul! ]

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How long does it take to make a MechaniCard? See one assembled from start to finish!

Have you seen the incredible new MechaniCard I posted about recently? If not, you'll want to watch that video before this one. You don't have to actually, but it will provide some good context.

In this video, creator Brad Litwin takes us through the process of making the Thumbs Up MechaniCard with the playback sped up. The video, along with Litwin's commentary, is a fascinating look at the intricate detail involved in this design. We also get to see some tools, materials, and techniques along the way -- making this an educational exercise as well.

I certainly learned a thing to two. I wasn't expecting so much hand-peening, but now that I've thought about it, it's clear that this is a inexpensive, strong, efficient and low-profile way to make a pivot for two or more parts.

Thanks to Brad Litwin for making this video.

To see the finished products, visit the MechaniCards.com web site.

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Frank Nelson, Artist and Automaton Maker (1930 - 2012)

It is with great sadness that we note the passing this month of Frank Nelson, one of the great makers of contemporary automata. I won't pretend that I knew him. Of course, I knew of his work and have always recognized it as some of the finest. Those who knew him have described him as a genius, who was inspirational, funny, and kind.

Like a few other luminaries in the field of automata-making, he was inspired by artist Sam Smith, who encouraged Nelson to try his hand and moving works and to enter them into exhibitions. Nelson, in turn, has inspired another generation of automata makers with his wit, fine carvings, and exquisite use of paint.

Frank Nelson's web site features a nice biography of his life as an artist. The passage below is taken from there.

Frank Nelson was born in Blackpool in 1930 and attended Blackpool Art School during the 1940s. He then spent some years in motor and aircraft design, becoming self-employed in 1960 and undertaking a range of model-making projects and design works for architects, museums film and theatre.

Frank Nelson started to carve and create automata in the early 1970's and for over 35 years he concentrated exclusively on automata with his own distinct figurative style using carved and painted wood. Over the years he has exhibited in most major galleries and art centres and acted as guest lecturer in a number of Universities, including the John Makepeace School for craftsmen in wood at Parnham House in Dorset. Many of his original automata are in public collections but of the many private commissions - he is proudest of the 'Barnum' automata commissioned by the actor Michael Crawford and based on the stage musical.

Nelson once described his piece 'The Tamer' (1975) as "the best idea I have ever had." The Tamer cracks his whip twice, but the big cat shakes its head from side to side, refusing to perform. On the third crack of the whip, the animal finally does the trick. The surprise comes in the form of a role reversal with the tiger putting his head into the Tamer's mouth.

Many of us who love automata own Frank Nelson a debt directly or indirectly. A man known for being generous with his time and knowledge, it is good to know that Frank Nelson's works will endure and his influence will live on.

Here is the official web site of Frank Nelson where you can see the paintings, drawings, portrait sculpture, and automata produced by this remarkable artist.

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Working replica of Mercedes from 1900 is powered by a Stirling engine

It's wonderful to see so many great bbooks and plans on Sterling Engines. Likewise there is a huge range of working Sterling Engine models around these days. Some of the nicest I've come across are those sold by Hammacher Schlemmer. Take for example the beautiful external combustion kraftwagen model I posted about last year. I don't know who exactly is producing these beautiful metal models for them, but they state that they are made in Germany.

This fully operational model is machine-tooled from solid brass, stainless steel, and aluminum. Power is supplied by the amazing Stirling Engine which uses the expansion and compression of air to turn the engine. An alcohol burner in the rear fuels the engine. These engines are remarkably efficient: full burner of ethyl alcohol allows the engine to operate for up to 15 minutes. Not keen on the idea of running an engine indoors. No worries: the exhaust is just steam and heat!

Here is where you can get the Mercedes model powered by a Stirling engine

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Upgrade light switches with these clever mechanical add-ons

The father and son team of Lance and L. J. Nybye have come up with a wonderful line of mechanical add-ons for common light-switch covers. The mechanisms are typically cut with a laser from high-quality plywood and finished off with brass hardware. Additional decorations are engraved/burned into the parts with the laser.

From the online shop:

These mechanical light switches transform an ordinary appliance into the perfect flourish for your secret library, steampunk chalet—or wherever your imagination lives!

The mechanical switch covers install easily over a standard switch plate using the existing screws. In addition to the excellent lever-based switch shown in the video, they have a couple of other lovely designs.

Here is their one based on planetary gears...

And another design based on the rack and pinion mechanism...

Here is where you can get these mechanical switch-plate covers.

[ Thanks Jan and Julia! ]

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Automaton of a turtle slowing coming out of its shell and being scared back into it

Check out this great wood automaton by Tony Anagnostopoulos. The piece took him two years to make, but it was worth the effort! He documents the process thoroughly on his blog.

Timing is critical to this piece. The slow movement of the turtle and the finger build up a lot of anticipation. The automaton's cycle is extended with the use of a worm and screw mechanism. A close up of one of one he made is shown below.

The fast reaction when the finger taps the turtle's shell is just what the piece needed for a finish to the cycle.

Here is a link to the Amateur Automata Maker blog.

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Marie Antoinette's clock and automaton to visit The Metropolitan Museum of Art

The Nemours Mansion and Gardens in Wilmington Delaware recently prepared a very special musical tall case clock for journey to The Metropolitan Museum of Art in New York City for a rare temporary exhibit starting at the end of this month. The clock is remarkable, as is its history.

Details about the clock from Steve Ryder:

This rare clock was made for Marie Antoinette c.1785, and it plays an organ and a dulcimer combined. Its case was made in the workshop of the German cabinetmakers Roentgen, who catered to the French Court, amongst others. The clock itself and portions of the musicwork are from the hands of Peter Kinzing of Neuwied, Germany. The musical mechanism was restored by my brother Jere Ryder with Arthur W.J.G. Ord-Hume in 1997, and ever since then, this clock has served as the musical show-stopper on museum tours of the Nemours Mansion, former home of the late Alfed I. DuPont. Jere was called in to prepare the clock for shipment.

The exhibition at The Met is entitled, Extravagant Inventions: The Princely Furniture of the Roentgens. It will feature some of the greatest works by Abraham Roentgen (1711-1793) and his son David Roentgen (1743-1807).

The exhibition will also feature an Automaton of Queen Marie Antoinette (1784), depicting a likeness of the queen at a clavichord. The automaton will be set in motion at select times during the exhibition.

The special exhibition will run from October 30, 2012 through January 27, 2013 at the Metropolitan.

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Get the "thumbs up" for any achievement with the turn of a hand-crank

Back in September, we had a sneak peek at the prototype of Brad Litwin's new MechaniCard titled Thumbs Up. The final version is done and here's the video to prove it. It looks even better with the final artwork.

Who would think that from a flat surface, a hand could rise, curl its fingers, and then raise its thumb -- all from the turn of a small hand crank? The mechanism is gorgeous, compact, and full of interesting components: gears, pulleys, belts, springs, strings, hinges, pivots, slides, and linkages. This one is shown with the optional display base.

Have you done something good lately? Do you know someone else who has accomplished something worthwhile? They deserve one of these.

Here is where you can see the full line of MechaniCards.

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Building Wooden Machines: Gears and Gadgets for the Adventurous Woodworker -- two classic books combined in one volume

Among all of the books on how to make wooden mechanisms, two of the best and most advanced have long been the two by Alan and Gill Bridgewater: Making Wooden Mechanical Models and Making More Wooden Mechanical Models: 13 Designs With Visible Wheels, Cranks, Pistons, Cogs and Cams. Originally published in 1995 and 1999, respectively, they have become increasingly hard to find, especially the second book which now fetches high prices in the used book market.

So, it is good news to learn that the two books have been combined into a single edition titled Building Wooden Machines: Gears and Gadgets for the Adventurous Woodworker.

Not intended for automaton makers specifically -- the stately models in this book showcase the inherent beauty of basic machines themselves. Indeed, any of these working models can be taken for kinetic sculptures that would be proudly displayed by the mechanically inclined person. If we were to leave the review at that, this book would be highly recommended.

Many of mechanisms found in Building Wooden Machines can be used for automata making. The following projects in the book are decidedly useful resources for the automata maker:

• Reciprocating Engine
• Rack and Pinion Machine
• Cam Machine
• Lever and Ratchet Mechanism
• Wheel and Worm Gear Mechanism
• Bicycle Chain Machine
• The Universal Joint

In fact, most of the projects could prove useful. Certainly some element of every project could be of value. The authors have great skill in fabrication with wood. They have a lot to teach in this regard. The methods of cutting, drilling, shaping, fastening, and finishing wood mechanisms can be applied very broadly. One little forewarning: some of the projects in this book require a wood lathe.

The new combined edition contains 28 ingenious woodworking projects with visible wheels, cranks, pistons and other moving parts made of wood. Each project has step-by-step instructions and plan drawings from which to work.

The original two books cost $22 and $25 each when they were published back in the 90s. This new combined edition is selling on Amazon for less than $18 right now. This is a great value no matter how you look at it.

Here is where you can order Building Wooden Machines: Gears and Gadgets for the Adventurous Woodworker. Be sure to check out the "Click to look inside" feature to peruse all of the mechanical wooden goodness within the pages of this new edition.

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Dug North's interview with Tested.com, the online home of Jamie Hyneman and Adam Savage

I was glad to see Norman Chan and Will Smith show up at my exhibit at Maker Faire last weekend. Will and Norm manage Tested.com, which is the official online home of Mythbusters Jamie Hyneman and Adam Savage.

Norman interviewed me on the spot. Here's how they describe the interview on the site:

Norm meets Dug North, a self-described "Kinetic Sculptor" who crafts wooden automaton sculptures. We learn about how automata work and Dug's process in bringing these elaborate wooden figures and dioramas to life.

The questions came fast. I did my best to keep up! During the interview, we cover a wide range of topics related to automata. I say a bit about automata in general, my process, my finished pieces, and what I plan to do next.

I've admired the Mythbusters since they first introduced their TV show back in 2003. For a guy like me, it is a huge honor to be featured on their site. My thanks go out to Norman, Will, Adam, and Jamie. It was a pleasure!

Here's a link to the interview on Tested.com.

UPDATE: Be sure to check out the follow-up article to this video interview in which I talk about the wood, tools, and techniques I use to make a wood automaton!

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The Electric Animal Circus: it's robots in a circus...what's not to like?

Any of my attempts to explain The Electric Animal Circus will fall short. As the title of the post implies, it involves a circus, robots, and a dose of humor.

Beyond watching the film above, their website says this:

Pozzo and Grotsky's Electric Animal Circus is a new type of live show: robot animals performing circus-inspired acts in a post-apocalyptic variety show. This website exists to showcase the project as it develops from concept to stage.

If you enjoyed the introductory film, here is one featuring The Great Maestro Pickleton and His Unusual Musical Octopus:

And while the film feels like something that might be a Kickstarter project, the web site says that the project is Financed by Deutsche Bank. I may be missing a joke here, but that's what it says.

[ Thanks Joe! ]

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Intricate spring-loaded mechanical sculptures that DON'T move

Cavity Mechanism #1 w/Glass Dome, 2008, Mixed, 10" x 7" x 7 "

Artist Dan Grayber creates these small, spring loaded, mechanical objects. I would embed a video for you but there is not much point. Read on.

At first sight it is obvious that some serious engineering and fabrication has taken place, but...nothing is happening. Or is it? Indeed, these mechanisms are actively doing something, but in this case a lack of motion is the goal. Using a variety of mechanical devices Grayber's creations will hold themselves up -- even within a smooth sided glass container.

From the artist's statement:

Objects are invented in order to satisfy particular needs, specifically, human needs. With my sculpture I investigate the concept of need when the human is removed from this equation. I do this by replacing the human with the object itself. My sculptures are invented only to sustain themselves, functioning as self-resolving problems. The result is an object that has been invented only to compensate for the complications created by its own existence. The piece alone represents the need and the resolution.

Here are a couple of other examples from the artist's web portfolio:

Cavity Mechanism #5 w/Glass Dome. 2009. Mixed. 6 " x 6 " x 6 "

Cavity Mechanism #2 w/Glass Dome, 2008, Mixed, 6" x 4" x 4"

The fabrication of these objects looks flawless. I love the consistent use of color and material, which helps to bring some very different things into a unified series.

I should point out that not all of Dan Grayber's work involves mechanical object under glass. He has created sculptures that will hold themselves to corners, concrete, drywall, gaps in walls, and between the floor and ceiling of a room.

Check out more of Dan Grayber's mechanical sculptures on his web site.

[ Thanks James! ]

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Hayling Billy steam railway wall mounted automaton by Tom Bennett

The piece shown above by artist Tom Bennett was commissioned to go in The Spring Arts and Heritage Centre Havant. It is a working representation of a the Hayling Billy steam railway, which operated between Havant and the holiday location of Hayling Island on the south coast for 100 years.

From the artist's web site:

The principal aim of the piece was bring to life the history of the railway in a way that would engage the imagination, particularly the young. It was to be part of a larger project designed to explore the history of the borough by means of a timeline, videos, artifacts and other interactive activities. Operated by hand and with the sounds of the engine chuffing and whistling, the train moves from past to present in a landscape filled with local history. On its way it passes tunnels, bridges, a turning windmill ending up at the seaside with bathers jumping up and down in the sea.

You can see more photographs and read about this autamaton and many other automata on Tom Bennett's web site.

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The politicians are everywhere...even in this automaton!

In this political time of year, it only seems fitting to feature an automaton depicting a (in)famous politician. Here's the first in a new series from Jim Kransberger titled Homage to Richard . I coudn't locate a video, so created this two-frame animation to give you a feel for what it does.

The automaton measures 7 inches x 9 inches x 3.5 inches. This piece is "exo-mechanical", which he explains is his way of saying that the mechanics are on the outside. Works for me!

The second photograph shows the back side of the piece and all the mechanical parts that make it move. I can't quite make out the exact details, but clearly there is a crank arm attached to the same axle as the hand crank on the front. When it is rotated down, it looks like it may pull on strings that run up to the arms via the U-shaped bracket. Or, perhaps it pulls the entire U-shaped assembly down. In either case, the pulling action causes the arms to raise at the hinges. Meanwhile, the same pulling action acts on a lever behind Richard's head, causing it to turn.

You can see more sculpture and automata by Jim Kransberger on his web site.

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Walter - a tinplate robot automaton by Marc Horovitz

Check out this awesome new automaton by Marc Horovitz of Sidestreet Bannerworks!

The automaton features an aging robot named Walter. When the crank is turned, Walter bends down to pick up the glasses he seems to have dropped. Sadly, he can't accomplish this task. Having knees certainly would help.

The robot figure is made of tinplate, using techniques found on the outstanding Tinplate Girl website. If you haven't checked it out yet, the site has a wealth of information about how to fabricate cool stuff with thin metal sheets.

Like many of us, Horovitz started making automata after being inspired by the work of Paul Spooner and other automaton makers associated with Cabaret Mechanical Theatre. His mechanisms are compact, elegant, and often elaborate -- not unlike Spooner's. The long cycle, subtle motions, compelling character, and witty storyline show that Horovitz has mastered the craft of contemporary automata making.

You can see more automata by Marc Horovitz on the Sidestreet Bannerworks website.

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Mekanikos vs. The Minotaur - automaton by Dug North at Maker Faire New York 2012

I promised more videos of my automata as well as some footage of the recent World Maker Faire New York 2012. Thanks to a visitor to my exhibit who took this video, I can show you both! This short clip shows me cranking one of my latest pieces which depicts a carnival sideshow scene titled Mekanikos vs. The Minotaur.

The automaton features Mekanikos (the world's strongest man according to the poster behind him) engaged in a struggle with a giant man-beast with horns. Turn the crank and the enraged Minotaur thrashes against the chains that bind him while Mekanikos uses his might to pull the monster back.

Below the stage another scene plays out. Clearly, there are two figures doing something, but what? And why? I'm going to leave those questions unanswered for now.

Each automaton I brought to Maker Faire had its admirers, but this one was undoubtedly the crowd favorite.

In the days to come, you can expect to see a far more detailed video of Mekanikos vs. The Minotaur.

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Automata by Dug North at World Maker Faire 2012

I participated in World Maker Faire New York for the first time this past weekend. Despite a bit of rain, it was a huge success all around.

Here's what my exhibit looked like moments before tens of thousands of people poured through the gates:

While I didn't get to see much of Maker Faire myself, I did get to meet a lot of people including fans, my favorite customer, readers, makers, Mark Frauenfelder, the awesome staff of MAKE magazine, Dale Dougherty (founder of MAKE Magazine and creator of Maker Faire), as well as fellow automaton-maker Philip Lowndes.

Here is a photo of my exhibit that I took quickly during a particularly slow moment. I received vast amounts of help from Julia Gavin and Bob Quinn (both shown behind the table in the photo below). I couldn't have done the show without them.

I won't kid you, it was all a lot of work, but it was well worth it for many reasons. I got to see thousands of faces -- young and old -- light up when the handles of my automata were cranked. That was tremendously gratifying. I also met many of you, the good readers of The Automata Blog. Thank you for coming by and for letting me know you enjoy the blog!

For those of you that couldn't make it, I'll be posting more videos of my automata on YouTube this week and perhaps even some footage of Maker Faire too!

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