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Outside-the-Box Solutions for Low-Cost Shop Equipment
By Craig MacKenzie, CP, RTP(c)
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Craig MacKenzie, CP, RTP(c) |
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Expensive does not always mean better. Ed
Patterson, who works at Velocity Labs, Orlando, Florida, was
cleaning the dishes one night and noticed that a frying pan and a
vacuum-pulling platen have the same shape. Most people either make
their own platens out of wood or buy the expensive aluminum ones.
The cast-iron frying pan has longer sloped sides and is extremely
durable. Plus, if the threads ever get cross-threaded, it is less
expensive to replace a three dollar, 1" flange.
Wal-Mart has several sizes to choose from, and they are all
inexpensive. To make the platen, cut off the handle of the frying
pan and smooth it off. Drill a 1" hole in the center of the pan,
place a 1" pipe flange centered on the hole, and mark the holes in
the flange on the pan. Drill and tap the holes with 1/4-20 threads.
Place duct seal in a ring around the flange, bolt the flange to the
frying pan, and grind down the bolts flush with the surface of the
pan.
Vacuum-Pulling Stations
 The vacuum-pulling stations that we have are all
made from parts purchased from the local hardware store, Wal-Mart,
and McMaster-Carr. The vacuum forming stations-four in all-are all
mounted on a table that is about 30" tall and 4x8 ft. The top and
legs are made from doubled 3/4" plywood and varnished. Each station
has the platen with a 20" section of 1" pipe connected to it and an
end cap. The end cap is drilled and taped for a hose fitting that
goes to a McMaster-Carr valve. The valve is mounted on a 8"x10"
section of plywood, which makes for a great $20 foot pedal, and
then is attached to a bunch of brass "T" hose fittings that connect
to the vacuum pump. The 20" section of pipe that is connected to
the platen slides through a 5" long section of 1 1/4" pipe and a 1
1/4" flange that is bolted to the table top. The 1 1/4" pipe is
drilled and tapped on the front and side for two screws that
tighten in on the 1" pipe and allow the platen to have some height
adjustment. The aluminum 16"x16" frames for the plastic were welded
at a local shop for $75, and all we had to add were the bolts and
wing nuts.
 The table has four vacuum-pulling stations for
blister molding and two stations for drape molding. The
drape-molding stations are made from 1" pipe 15" long with an end
cap that is drilled and tapped for a hose fitting at the end. We
had a local welding shop weld the pipe to a section of 3/8" steel
upright that was 4"x6" and then weld that piece of steel
perpendicular to the base. A 3/8" nut was welded to the top of the
pipe over a hole to allow a knob to hold the plaster cast in the
pipe. Total cost for welding and steel was $50 each. Each
drape-molding station is connected to a simple gate valve that is
mounted underneath the table at the front edge for easy access.
Lamination Stands
 The lamination stands are also simple to make. A
20"x20", 3/16" thick section of steel is the base, with a 2" pipe
flange bolted to the center sealed with duct seal. Screwed into the
flange is a 40" section of 2" pipe with a 3/8" pipe screwed into
the side of it about 20" up. The 3/8" pipe has a gate valve
attached and is connected to a vacuum source. At the top of the 2"
to 1" pipe is a reducer that is drilled and tapped with for two
3/8" allen cap screws. The screws tighten on the cast to hold it in
place during lamination. In the top of the reducer is a 3" section
of 1" pipe that stabilizes the cast. Bolted in one corner of the
base is a 1/2" pipe flange with an 8-foot section of 1/2" pipe.
Connected to the 1/2" pipe is a 90-degree elbow with another 12"
section of 1/2" pipe that holds a clip over the center of the stand
to hold the PVA bag or funnel during lamination. This stand allows
the user to walk around the entire lamination. Attaching the bag
clip to a weight and pulley allows the user to keep an even pull on
the bag and adjust for different height laminations.
 By removing the reducer, shortening the 2" pipe,
removing the 1/2" pipe assembly from the lamination stand, and
adding the foot pedal in place of the gate valve, you can turn the
lamination stand into a great standalone blister-forming
station.
Supplies List
Blister-forming station table
version
- One frying pan-you choose the size
- One 1" pipe flange
- One 20" long section of 1" pipe
- One 1" pipe cap
- One barb hose fitting
- One 1 1/4" pipe flange
- One 5" long section of 1 1/4" pipe
- One McMaster-Carr valve (4625K61 squeeze lever - $27)
Lamination Station
- One 20"x20" 3/16" thick steel
- One 2" pipe flange
- One 40" long section of 2" pipe
- One 2" to 1" reducer
- One 3" long section of 1" pipe
- One 8" long section of 1/2" pipe
- One 12" long section of 1/2" pipe
- One 1/2" 90-degree elbow
- One 1 1/4" long section of 3/8" pipe
- One gate valve
Drape-molding station
- One 15" long section of 1" pipe
- Two 6"x6" 3/8" thick steel plates
- One 1" pipe cap
- One gate valve
- One 3/8" nut
- One 3/8" knob
Blister-forming station standalone
version
- One frying pan-you choose the size
- One 20"x20" 3/16" thick steel
- One 40" long section of 2" pipe
- One 2" pipe flange
- One 2" to 1" reducer
- One 3" long section of 1" pipe
- One barb hose fitting
- One McMaster-Carr valve (4625K61 squeeze lever)
Craig MacKenzie is the owner of Velocity Labs Inc., Orlando,
Florida, and president of Evolution Liners Inc., Orlando. Prior to
his current positions, he was director of research and development
for TEC Interface Systems in Minnesota and senior technician at
Sunnybrook Center for Independent Living, Toronto, Ontario, Canada.
He can be contacted at:craigm@velocity-labs.com 
Table Of Contents - August 2005
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