Crazy Monkey Woodshop

May 27, 2010

So This is May, What Have We Done?

It’s been over a month now since I first got the CNC router mostly functional (and since I posted an article), and I am sure you are all eager to know what’s going on with that. Actually, I’m pretty sure most of you are eager to know what the hell I’m talking about in the first place, and really why you should care at all.

What on earth is a CNC Router, you ask? Why should my loyal and future customers care that I have one? What does this mean to them? What does this have to do with the price of tea in China? I’ll answer the last question first, since it is the easiest. Nothing. There I said it. My CNC router will have no effect on the price of tea in China, as far as I know.

Now on to the harder questions: A CNC Router is a router, which is controlled by a computer. A router is a woodworking machine which spins a small bit around, very fast, to cut through wood. The computer control enables the machine to cut out virtually any kind of complex shape. This has some interesting ramifications for us here at Crazy Monkey Creations, and by extension for our customers.

First, the CNC Router does its work in a semi-unattended way, freeing all of the Crazy Monkey employees (i.e. Me and sometimes Christy) to work on other parts of the production while waiting for the CNC to finish its part. This should hopefully more than double our production capacity, so eventually it will mean shorter lead times for our customers.

Second, the CNC Router can cut a curvy complex shape every bit as easily and quickly as a simple square boxy shape. This capacity will be put to great use in the near future and we are working hard to redesign our product line to make full use of this new capability. Our new products, which we will start announcing in Late July or early August, should be much more attractive, fluid shapes, which hopefully you will find to be as pretty as they are functional. Of course we will continue to make unsurpassed usability our primary design concern.

Third, since the CNC Router can cut complex shapes easily we can use this functionality to implement new and better features for our products. Features that have in the past been too difficult or time consuming for us to include at a practical price will now be implemented nearly for free. This will greatly increase the value of our products to our customers. One such feature will be finer graduations for the winder arm markings, making it easier for operators to set a specific skein size.

Fourth, we will be able to make more efficient use of our materials, since we will be able to cut parts out in a nested fashion. This will of course help us keep costs down, and it also help save the environment by producing less waste. We are always as efficient with out materials as we can be of course, and now we can be even more so.

Fifth, the CNC Router will enable us to make products that were simply impossible for us to make in the past. We are working hard on expanding our product line. In addition to releasing the redesigned skein winders and swifts from our current collection, we will be introducing many new products over the next few months.

So, as we learn to use our CNC Router to its fullest capability, and as I continue to rebuild it to increase its rigidity, capacity and reliability, we will be making more and better products available to you, our loyal customers.

9 Winders and 2 Swifts

If you ordered a winder or swift recently, it’s on this table.

April 25, 2010

CNC Router’s First Real Cut

Filed under: CNC Router, Tools — Tags: , , — Ben @ 10:55 pm

I “finished” the CNC router yesterday and have gotten a chance to try it out this afternoon. As you can see in the video, it works ok but it does have some serious problems.  I am going to have to rebuild the gantry structure to increase the rigidity and reduce the leverage of the Z axis. Luckily with my new-found experience and of course the help of the CNC router itself, this shouldn’t be too terribly difficult of a task.

April 13, 2010

Slow and Steady Progress…

Filed under: Drop Spindles, General, Products — Tags: , , — christy @ 5:57 am

At least on my part. Ben finished up 2 winders and a double swift today (and they’re getting shipped today). I, on the other hand, only turned one spindle. To be fair, I did vacuum out the car and clean some of the mud out of it while Ben was working. Yesterday, we went to Collector’s Specialty Woods in Gardner, CO. Here’s some of what we got. (More after the jump).

Boards from Collectors Specialty Woods

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April 10, 2010

The Beginings of a CNC Router

Filed under: CNC Router, Tools — Ben @ 9:00 am

It’s official, I have started building our CNC Router. When it is finished, we will be able to expand our product lines as well as improve our existing products. We already have a big list of what we will be selling once the CNC router is fully operational.

So far I have built the Z axis and half of the Y axis.

Z Axis

Z Axis

Z Axis

Z Axis

April 5, 2010

A better tour of the shop …

Filed under: General — christy @ 2:37 am

Benny showed you what the shop looked like before we went and freed some of our imprisoned tools from the storage unit we’ve been keeping them in (in the back, behind all of the rest of our stuff), and while the Moving of the Table Saw was dramatic (and traumatic), the best picture I have of that day is this one:

Muddy hand

That was my hand after digging out the car from the mud, probably the first or second time. And this is the cleanest it was for the rest of the day.

So, the tour… Let’s start at the right side of the shop. Photos after the jump This post is picture heavy, so if you’re on a slower connection, you may want to click and grab a cup of coffee (or tea).

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March 26, 2010

One Down

Filed under: General — Ben @ 5:43 pm

I managed to finish the first skein winder in the new shop today. It feels good to be productive again. In addition to finishing and packing the one winder, I did work on a stack of arms and fingers and worked on organizing the shop some more.  I think I will have to move the table saw to the other side of the room, but I’m not sure. It’s amazing how much room just that single tool takes up.

Here are a couple pictures of the shop so far.

Shop Seen From One Corner

Shop as Seen From Another Corner

March 25, 2010

The Shop is Now Operational

Filed under: General, Tools, Yarn Winders — Ben @ 9:43 pm

I have managed to get my table saw rebuilt and calibrated, and I have built a new assembly table. Those are the two biggest tasks that needed to be done before I can actually use the shop for any production work. So now I will start finishing the winders that have already been ordered, and working on building up a back stock of parts again, while also working on putting together the rest of the shop. We are going to get some more of our tools out of storage (not at The Ranch) this weekend, so it won’t be long before it starts feeling like a real woodshop.

Among the many tools which will be retrieved from storage is our lathe. some of you my be able to guess at the ramifications this will bring, some of you will just have to wait and see the awesomeness as it is produced.

The heater seams to work well, and even on cold days the temp is well over 50º. The large thermal mass of the concrete and earth keep the room from getting too cold, so my glue will be safe there. A good thing, as I am tired of replacing frozen glue. This will sure beat working in the refrigerator/freezer that was the ranch shed this winter.

Construction of my new CNC router which I still haven’t told you about should begin sometime next week too, at which time I will actually tell you about it. This will eventually be the most exciting news on this blog.

In other news: We are switching to a new motor for our electric skein winders. This motor is more powerful, quieter, smoother, and American made. However it does cost more than the old motor did, and so the price of the electric winders will be going up by about $50. The motor mounts to the winder a little differently, so I  have yet to build a prototype of the new mount design. This should happen on Sunday or Monday, and once I have the prototype finished and tested, I will officially announce the new price and design. Any winders ordered now will receive the new motor, but we will continue charging the old price until we officially make the announcement on the Crazy Monkey News web page. This is effectively a $50 off sale! Hurry because the official announcement  and price increase will probably happen late next week.

March 23, 2010

Tools Out for Summer

Filed under: Tools — Ben @ 12:40 pm

Well, yesterday was a “good” day.

Round about 2:00 we headed out for the ranch in a last ditch effort  to extricate my tools. We made it to the gate around 4:00 and began with the interesting bit. It took about and hour and a half to travel the 2 miles, but with the help of our 14 new traction pads ($7.50 per pair) we made it all the way to the shed where all the tools were.

At the Shed, Loading Tools

Once at our destination, we loaded up the table saw, drill press, router table, routers and various odds and ends. Loading didn’t take too long, and we were on our way, just as the sun started setting. Loaded down with tools, the way out proved to be more difficult.

As we approached the one truly hard part of the route, we became unable to proceed forward, on perfectly level ground.  So, once again, we deployed our 13 traction pads and inched our way forward. Then, we made it safely down the super muddy hill, and even most of the way up the other side.  Enter the dozen traction pads and about 15 minutes of effort.  From here on, the journey went very smoothly… until I slid sideways into a ditch and really high centered the car. Once again, our 12 traction pads came to our rescue, this time with the noble assistance of the car jack. We left this spot with 6 of the pads, and drove another 50 feet before the car simply would not go any farther.

Everything we tried failed, which was really frustrating because this was not one of the “problem spots”. I walked back, found and dug out some more of the pads, bringing us back up to 11, but they just didn’t help. We even tried unloading most of the tools, laying them out in the mud, this had zero effect.

By now it was 10:30 and we weren’t getting anywhere.  So, I called the very nice people at the Huerfano County Sheriff’s office and they gave me the number of a tow company. The nice guy at the tow company agreed to come out in his own vehicle, an old 4×4 Bronco with huge mud tires to pull us out.

We very hurriedly loaded the tools back into the car, and proceeded to walk the remaining mile to the road so we could show him where the gate was. We got to the gate at almost exactly the same time as him. Christy and I piled into the Bronco and rode back to the poor stuck Element.

Once at the Element, the guy put his Bronco into 4 wheel drive, hooked up a chain, and pulled me down the hill, and out into the field, where I got stuck again, and again, even with him pulling me. We tried everything, and with lots of yanking, tugging and mud flinging, we made it up the hill.

Finally at the top of the hill and on dry ground, I ventured forth under my own power. The car still didn’t want to move! It turns out the back wheels were so full of mud they didn’t want to turn. But, after a few revs and popping the clutch, we were on our way. Back on dry, rocky soil, the wheels cleared out quickly enough, and I drove most of the remaining way out under my own power.  I did get superficially stuck one more time so the guy came back and pulled me out again.

Finally, we were all back at the gate, back on dry ground, and had no more mud to contend with. We agreed to follow the tow truck guy into Walsenburg to get cash from the ATM so we could pay him for all his hard work. Round about midnight, I very happily handed over $260, and we were all glad it was over, except of course the 3 hour drive home.

At the Gas Station, Covered in Mud

It was a very good day.


Epilog

In the end, I knew where 5 of the traction pads were, and that’s probably where they still are.

March 20, 2010

Tools Stranded

Filed under: Tools — Ben @ 8:02 pm

Last night’s mission to extract the tools from the ranch failed.  I didn’t even make it in 200 feet.  I spent over 10 hours driving in nasty and varying winter conditions, passed more than a few horrible looking crashes, and plenty more cars stranded along the road, and in the end, I failed to get my tools.  Judging from the weather report, the current snow load and current moisture content of the ground, the ranch will not be accessible by my vehicle for at least another couple months.  This of course means that at this exact moment I am paying rent on an empty shop, and do not have any of the tools needed to produce skein winders.

So, now I have a few possible options for Plan B:

  1. Pay someone with a Unimog or Pinzgauer to drive into the ranch and get my tools.
  2. Buy a Unimog, Pinzgauer or Haflinger
  3. Buy tank tracks for the Element
  4. Buy all new tools
  5. Buy used tools from a pawnshop
  6. Borrow tools and shop space from a neighbor until I can get my tools
  7. Borrow tools to build the CNC router, which will then do all the work and I won’t need my tools
  8. Try again with the Element in the mud instead of the snow

I am open to any other solutions anyone may have.  Once a solution is found, winder production will resume on a fairly short lead time.

March 18, 2010

A New Home

Filed under: General, Products, Tools, Yarn Winders — Ben @ 2:27 pm

It’s official, we now have a new home, and perhaps even a new hope.   I have just rented a 600 sqft woodshop just a couple miles north of our house in Denver.  This means that once we move the tools, we won’t have to drive down the The Ranch every time we want to build something.  This will have far reaching repercussions on our production time, our R&D and also on the kinds of products we will be able to offer in the near future.

Our New Shop

Look for the lead time on winder production to drop back down to a week here pretty soon, once we get the tools re-calibrated after the move.

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