Boxford Resources System

This project introduces jewellry manufacture to the department.

At Keystage 3 I would spend some time looking at the different tumbling rocks, particularly semi- precious stones.

Depending on the output from the tumbler, I would buy some polished stones or go for an off the shelf bead set. At year 7 I would look at making a necklace. If the budget is tight I may look at laser cutting beads from the smallest acrylic offcuts.

At year 8 I would be looking at adding some metal backing possibly brass sheet, this is where blagging material can make all the difference.

At year 9 I would like to add metal and enamelling to produce a very colourful result.

At keystage 4 I would expect the pupils having had the previous instruction to be able to design a simple brooch. However, by now I would expect them to be wanting to make their own design statements, for this reason I introduce the Steampunk solutions, everything they make are recovered mechanisms, I think they look glorious and if I was younger I would drape myself in this stuff. I may feign a mid life crisis so that I can wear it yet.

Tumbler

Tumbler Tumbler

Tumbler

Polished Stones

Stones

Stone polishing or lapidary has been part of what was CDT since I was at school. There is a strange draw to simulating the action of tides and rivers to take a rough hewn stone and wear it down to a shiny pebble.

There are also the cross curricular links to science including geography (origin of the stone), Geology (characteristics of the stones) and science in general (Weathering - tidal actions - long shore drift and its implication to holiday resorts etc.)

Not to mention the number of jewelry projects that can be undertaken with stones created in the department.

Stone can be purchased in a number of conditions and styles and is approximately £5 per pack.

TUMBLING QUARTZ MIX (Pack of 700gms)

Mixed Rocks

TUMBLING AGATE MIX (Pack of 700gms)

Rocks

Many supplier exist and can be found by googling "Lapidary Supplies" Or "Rock Tumbler" - Ebay also has a wealth of suppliers.

Secondly you will need some abrasive this can be bought in many grits but starting with an 80 grit then after the bulk of the work has been done 400grit followed by polish.

A 1 kilo pack (enough for about 10 runs) is about £17.

Next you will need a tumbling chamber the cheapest system I have been able to find which is watertight under all circumstances is a double ended 110 sewer connecter, with two end caps. (cost about £6). You will need at least two as the polish should never be used in a grit tumbler as it binds all the abrasive together.

1 Off - 110mm Underground Drainage Sewer Coupler

2 Off - 110mm Underground Drainage Sewer 2 in 1 Cap & Plug

Pipes

It is wise to drill a small hole in the centre of one end piece to equalise the pressure during assembly then block it with a pin.

Finally the motor drive.

Two models are presented here one for the 1:100 como drills motor (which did struggle and eventually shattered).

The second (top picture) for a 60rpm geared motor bought from ebay.

A third model is in development for the large e series motor and will be added soon.

1:100 Como drill Model.

1:100

2D Design Drawing

Design1

Above Design - Download

60RPM Geared Unit From Ebay

60RPM

Tumbler

Above Design - Download

Common Components

The unit uses four 4001 bearings 10mm I.D. 26mm O.D. Considering the number of rotations the unit will make in its life these are almost essential.

Turned Wheel Mounts

3 off style 1 - Boxford PRF File - Download

1 off style 2 - Boxford PRF File - Download

The wheel mounts each take two cut final drive disks on the end with the hole drilled into it.(on the 1:100 model the stepped sides of the drive disks go to the middle to make a pulley) the 10 diameter goes through the 4 bearings. The Style 2 piece has an additional shaft designed for the coupling to drive.

Finally the shafts are joined with a 5mm bar both ends inserted into the 20mm deep hole to both space the shafts out, helping support them and transferee the drive energy.

The coupling is made from two brass turnings and five pieces of 3mm acrylic.

Coupling

Cut the acrylic and bolt all five together with 3mm / 25mm bolts with 3mm nyloc nuts. The solid disk must be in the centre.

The brass sections are turned from 19mm hexagonal bar, this gives the six sided drive without needing a milling process.

The centre holes are drilled to suit the motor shaft and the 7mm additions on the Style 2 shaft.

Coupling

Boxford Lathe File for Bosses - Download

2D Draw files for laser parts. - Download