Rebuilding My Excalubur EX21 Scroll Saw

This isn't a how-to or tutorial. Although in hindsight, it could have been if I had taken the time to take a bunch of photos.

Excalibur EX21 Scroll Saw With Table Removed

This all started when I was cutting a project on my scroll saw, and it suddenly began making a knocking sound and vibrating badly. So bad that the blower tube was bouncing off the table. Slowing it down very slow let me finish what I was doing.

After some troubleshooting with tech support, I determined that the noise and vibration were caused by an accumulation of wear in the various bearings. There are eleven bearings in this saw.

Excalibur EX21 Scroll Saw Rocker Arm Attachment

I could have ordered parts one or two at a time until I found the right part, but since we are fast approaching Christmas I bought complete assemblies and replaced all the moving parts except the motor.

The photos were nearly unusable. Some things were completely missing. There were no instructions for removing and replacing the front rocker arm assemblies.  The instructions would tell you to loosen a screw when what they meant was to remove the screw.  Also, they didn't tell you about the four other screws you had to remove. I knew I was in trouble when I read the part that said to use an adjustable wrench. The instructions were obviously written by someone who already knew how to do this and not tested or proofed by a person who had never done it.  The instructions told you how to take it apart but very little about how to reassemble every thing.

Excalibur EX21 Scroll Saw Rocker Arm Attachment

You can put the assembly in upside down. I'm real good at taking this saw apart now.

I knew there was going to be trouble when I read the part about using an adjustable wrench. Adjustable wrenches are for using on the occasional odd size fastener or fitting you might run across. I would never use an adjustable wrench to work on an $800 tool. It is to easy to break or round off a fastener that you can't easily replace. I have several, but they stay on the tool board and only get used as a last resort. If you want to do quality work, you use the right tools.

Excalibur EX21 Scroll Saw Rocker Arm Attachment

Why do they make things with a mix of metric and SAE fasteners? I spent way to much time trying to figure out which wrench to use. Especialy the cap screws.

Then there was my usual dropping parts and crawling around the floor looking for them. One thing I learned while searching for a tiny part was that my DeWalt Spotlight (DCL043) works great for finding parts. It lights up my floor like daylight. 

Excalibur EX21 Scroll Saw Rocker Arm Attachment

The saw runs great now. I don't know if it is like new since I bought it used. This is the second saw I purchased used. My next saw will be a new one. Both of the scroll saws wound up needing to be refurbished. This one (EX21) wound up, costing me almost as much as buying a new one. My other saw is an older RBI Hawk that I purchased for $100 and spend $200 on, so it was still a bargain of sorts.

I didn't take many photos these were taken so I could see how to put things back together. 

--

Etsy Listing - Handmade Wooden Ghost Cutout Custom Sizes Available Made To Your Specification 540504790

Custom handmade Halloween cutouts made from wood or wood products made to your specifications. Sizes available up to eight inches and thicknesses from 1/4-inch to 1-1/2-inch. Larger sizes are possible. Material choices include pine, oak, poplar, MDF, and plywood.

Do you have an idea for a ghost that you don't see anywhere? If you can draw it, I can probably cut it for you.

The sample size shown in the photos below is currently available for purchase on my Etsy shop. If the size or materials are not what you want, contact me through my Etsy shop to place a custom order

These make great pretend Halloween toys for kids. My grandson has an entire set of them and was my inspiration when I made the first ghosts.



Click here for this listing.

Click here to see my other Halloween items.

Click here go to my shops front page.

Handmade Wooden Toy Halloween Ghost Cutout Silhouette On My Work Bench

Handmade Wooden Toy Halloween Ghost Cutout Silhouette Front View

Handmade Wooden Toy Halloween Ghost Cutout Silhouette Size

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette

Handmade Wooden Toy Halloween Ghost Cutout Silhouette Size on Ruler

Handmade Wooden Toy Halloween Ghost Cutout Silhouette Size On Ruler

Handmade Wooden Toy Halloween Ghost Cutout Silhouette Size On Ruler

Handmade Wood Halloween Ghost Cutout Made From Solid Pine Wood Custom Made To Order 643250709

Use these ghosts to make Halloween decorations, mobiles, ornaments, toys, or cake decorations. Use several or mix and match with other cutouts and create unique items.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

A handmade, unfinished 3/4-inch thick Halloween Ghost cut by hand on a scroll saw. It has been lightly sanded with 220 grit sandpaper and is ready to be painted. Use the ghosts as is or paint them. The kids always want colors. Unlike many thinner cutouts, these are freestanding and are good pretend toys.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

I can easily make these in any size up to eight inches. Sizes above eight inches require a custom printed pattern at additional cost.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

Hardwood, plywood, and MDF are a few of the materials I can cut ghosts from. Some materials will cost a bit more. Custom orders are always welcome.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

Click this link to see more Halloween items:
https://www.etsy.com/shop/OdinsToyFactory/?section_id=22228027



I made the first batch of these for my grandson, Odin. He is crazy for anything Halloween related. Some friends saw them and wanted them too. They are great Halloween decorations, but, for my grandson, they are toys. He builds haunted houses from blocks and uses them as scary occupants.



This toy is not for use by children under three or children who like to chew on things.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

I recommend sealing with shellac before applying craft paint. You can use craft paint without sealing. However, it will require more painting and more sanding to get a smooth finish. If sealed and painted, wooden Ghosts are safe for outdoor use.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

Another option for painting is Behr exterior house paint. You can get it in small sample cans at Home Depot in just about any color you can imagine. Other hardware, home centers, and paint stores offer similar samples.

Height 3.5 inches
Width 3.5 inches
Thickness 0.75 inch

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

These Ghosts are handmade from real wood. Each piece, even from the same board, is different. The one you receive may not look the same as the one in the listing photos.

Handmade Halloween Wooden Toy Ghost Cutout Made From Pine Wood

I sell these individually instead of in sets so you can pick and choose only the ones you want. Shipping per item gets lower as you buy more of them.

Free Shipping for purchases over $35.

 

 

Wooden Wheel Patterns for the Scroll Saw

Wooden Toy Wheel Patterns Ready To Cut With A Scroll Saw

I salvaged the wood from 2x4 pieces that would typically go into the burn bucket and used for kindling the next time we have a backyard fire. Because the wheels are so small, it is simple to work around defects such as knots and pitch pockets. I resaw the wood to 1/2-inch thick on my Shopsmith band saw, sand the wood on the belt sander, apply the blue tape, and the patterns. I drill using a drill press and a very sharp brad point drill bit getting as close to the center as possible.

I have tried several methods for drawing the circles on the wood using printed patterns is by far the most accurate way to do it.

The blue painter's tape lets me remove the patterns with little fuss, leaves no residue, and lubricates the scroll saw blade.

I made a pattern to print 35 wheels on a page. I used two and a half pages and made 88 wheels. There are always a few that are don't come out well, but the yield was very high for this batch.

Click here to get a copy of the pattern I used to make these wheels.

Toy Makers Shop - Dust Collection For My Sanding Mop Made From PVC Pipe Coupler

Pipe Coupler Dust Collector Mounted ON My Harbor Freight Drill Press with a Sanding Mop

In my toy making shop, I use a sanding mop a lot. It makes a considerable amount of fine dust, that is hard to collect. The 2x4 PVC pipe coupling is the best solution I have found so far. It is straightforward to build and costs about $10 if you don't already have the parts.

To make the collector drill a hole in the 2x4 pipe coupling and bolt on a magnet. Then connect your shop vac. If you don't have a cast iron top an electrical box cover screwed to a piece of plywood or MDF will give you something to clamp.

I used a magnet from a previous project that I didn't need anymore. I  got mine from Harbor Freight, but they are available from Amazon and eBay if you don't have a Harbor Freight store. Warning, Test your magnet to be sure you can get it off. The one I used sticks so tight I needed a pry bar to get it off. This project is a good candidate for mag switches if you move it around a lot.

All vacuum hoses will not fit tightly. I have an extension hose for my shop vac the fits tight on the inside of the coupler. However, the regular hose end is a little too small. You may need to make an adapter.

This contraption works very well as compare to what I used to do. Nothing or clamp the shop vac hose to the table and hop it stays put. The vacuum hose worked, but it was quite tricky to keep in place. The Pipe coupler with this magnet isn't going anywhere. The hose will pull out before it moves.

Tools for the Toy Maker

I make toys and fretwork. Here is my take.

1. Workbench with a Vise

It doesn't have to be fancy, but you can't work without it.

2. Drill Press

Everything I do uses a drill press in some form or another. Drilling, hole saw for making wheels and sanding with various attachments.  Sanding mops are a must have in my shop. You can use it as a drum sander, and there are many attachments that you can buy or make for it.

3. Belt Sander

I have a 1" x 42" Delta Belt and disk sander. This one is very much like it. I also have a 6x48-inch belt sander. One or both of these get used on every project. I don't find the disk sander to be very useful.

4. Saw - Type depends on the situation.

You need to cut wood  Provided you can get the wood in the thickness you need. There are many options. If all you are doing is scrollsaw projects, a hand saw will work. You can use a scroll saw in place of a bandsaw for everything but resawing lumber. You can use a scroll saw for cross-cutting and ripping with the proper blades but only for smaller pieces of wood. I some times cut parts from 3/4-inch stock and resaw them to get the appropriate thickness. I have a table saw that I rarely use. I break down larger stock with a battery powered circular saw and straight edges and cut the rest with a 12-inch sliding compound miter saw. If you set it up right, you can cut just about any size you need square and safe. Resawing with a bandsaw is not something for beginners and you really need to add jointers and planers to this.

5.


Steves List
1. Table saw.
2. Disc/Belt Sander
3. Drill press
4. Workbench
5. Planer
6. Band saw
7. Drum sander
8. Jointer.

--
Odin's Toy Factory Etsy Store
Google Photos Toys Album
Odin's Toy Factory Blog
Pinterest
Facebook
LinkedIn
YouTube
--
The right to buy weapons is the right to be free.
                            -- A E van Vogt
                            Weapon Shops of Isher

Tool Review - Harbor Freight - Pittsburg 4 inch Ratcheting Bar Clamp

Harbor Freight - Pittsburgh 4 inch Ratcheting Bar Clamp

The first one of these I ever saw was the next larger size. I purchased some and discovered that the clamps would not hold. I could clamp hem down tight, and a short time later I would find the clamp had loosened. I finally gave up on them when one broke and tossed them in the recycle bins.

Several times over the last few years, I tried them again in the store and found that they broke easily and would not clamp tightly. I got a deal on some Irwin clamps and didn't look at them again.

The one day I received an email from a trusted friend telling me how great the 4-inch clamps worked and that with a coupon I could buy them for $0.99 each. I build toys, and when I am making a large batch of them, I sometimes run out of small clamps. For $0.99 I had to give these a try.

They must not make many of the Pittsburg 4-inch clamps, or they are in high demand because I had to stop by the store several times to get five of them.

Once I got them in the shop and had a chance to play around with them a bit, I found that they worked quite well. Better than the small much more expensive Irwin clamps I have. The best clamps I have in this size and type are DeWalt clamps. So far the Pittsburg Clamps are on par with the DeWalt clamps.

During the first real glue up the clamps slipped just like the old ones and I had to use the DeWalt clamps. What happened? They worked good when I was testing them. Something had to have changed.

I eventually figured out why they slipped. It was my fault. For years I have routinely put johnsons Paste wax on my clamps to keep the glue from sticking to them. Wax on the bar clamps never caused a problem for me before because I was using clamps that had multiple clutch plates and grooves cut in the metal for them to grab. Waxing the Pittsburg Ratcheting Bar Clamps will make them slip.

The fix was easy.  Using a blue paper towel and some mineral spirits, I gave the clamps a good cleaning. After the mineral spirits evaporated, the Pittsburg clamps worked great.

If you need some small light duty clamps, it's hard to go wrong with these. With a coupon, they are only $0.99 each. Without a coupon, they cost $1.49. My DeWalt Trigger Clamps cost $4.99 each, and I had to buy a dozen of them to get that price. The DeWalt clamps are $5.97 each a Home Depot. The IRWIN Micro Handed 2-Pack Clamps are $12.98 for two at Lowes.

On price alone, the Pittsburg clamps are hard to beat but add in Lifetime in-store replacement warranty, and this makes these clamps a must-have for toymakers.