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DanoNJ
03-17-2013, 05:57 PM
New for 2013, I started the build on a carousel. Unit will be just under 5' wide and about 5' high. I basing the build on plans I purchased from Winfield and will be completing some modifications.

First step was to make the base which is simply some 2x6s. I made some wooden gears (a bit of a pain to cut out and make fit well). The main gear sits on a lazy susan.

DanoNJ
03-17-2013, 06:01 PM
Of course I'm using a wiper motor for power running at 5vdc. These pictures show the motor housing and main gear on the base frame.

DanoNJ
03-17-2013, 06:03 PM
Floor sides cut.
And the floor joists.

DanoNJ
03-17-2013, 06:06 PM
Center colum. The stringers have to be cut on an angle. The colum will be held in place by L's which have to be set into the strigers.
Picture shows the inside of the colum before the skin is applied and the finished product.

DanoNJ
03-17-2013, 06:08 PM
Short video of the gears - test mode.

http://www.youtube.com/watch?v=61iH2a1w45k&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=3

DanoNJ
03-17-2013, 06:08 PM
another short video of the floor on the base.

http://www.youtube.com/watch?v=DQOoYOiZb08&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=2

DanoNJ
03-17-2013, 06:11 PM
Here is a picture of the base w/ gears. The center post adds some stability to the upper part of the unit. It does not get attached to anything, the colum slides over top.

The other picture is the top. From each of those will be attached the roof rafters.

DanoNJ
03-17-2013, 06:14 PM
I made the decison to go with some 3/4" box steel for the roof suports to help with the possible sag / warp issue. What I did was cut to length and drilled and tapped one end. This end will be attached to the center support board. This makes up the bottom section of the roof structure.

DanoNJ
03-17-2013, 06:19 PM
On to the rafters. You'll get a better understand of the topper picture posted earlier now.
And a dry fit of the parts.

mpurser
03-17-2013, 06:55 PM
sorry all the links to videos are bad you tube says video does not exist

DanoNJ
03-17-2013, 07:02 PM
The end of the roof rafter are also beveled to accept the side panels. Top top of the side panels are beveled to accept the roof.

DanoNJ
03-17-2013, 07:06 PM
Roof panel

DanoNJ
03-17-2013, 07:15 PM
I not only want the unit to spin, but I wanted some (there will be six) of the characters to go up and down, just like a real carousel. To make this happen, I made a circle of 1/2" ply around the base of the unit. In order to bend the ply, I had to score the underside multiple times. This way the ply would bend without cracking. Now, I can cut some curve in there.

DanoNJ
03-17-2013, 07:17 PM
So, how will these characters move? Each of the isx will be attached to a length of 3/4" PVC pipe that runs from the floor to the roof. Three of these, the ones moving, have a length of 1/2" box tube inside. Attached to the box steel is a wheel from a roller skate. The wheel is attached to the box with a piece of metal welded on.

a picture shot up underneath to give an idea on how the wheel will 'ride' on the plywood.

DanoNJ
03-17-2013, 07:20 PM
The video shows the unit spining clockwise. I have since changed the direction, but you get the idea.....
http://www.youtube.com/watch?v=_4HysZyMLUE&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=1

aaron1
03-18-2013, 01:36 PM
Amazing. Can't wait to see the characters you're adding.

jklingert
03-18-2013, 01:41 PM
Amazing job Dano!! I can't wait to see the finished carousel.

DanoNJ
03-18-2013, 09:16 PM
More build.

Jeff Millard
03-23-2013, 02:28 PM
Dan,

That's beautiful. I was wondering why the wipers stopped working in my F-150...

Jeff

DanoNJ
03-23-2013, 04:57 PM
Dan,

That's beautiful. I was wondering why the wipers stopped working in my F-150...

Jeff
Did you really need to wonder?? Thanks, Jeff.

mkozik1
03-24-2013, 10:53 AM
The wife has been asking me to build one of these for some time now and I could not figure out the best way to do it until now! Looks like I have my summer project! Thanks for the great tutorial.

tfischer
03-24-2013, 02:25 PM
Very cool project!

DanoNJ
03-24-2013, 07:24 PM
The gang's all here! Cut out the characters and first coat of primer. Next is a light sanding and another coat.

dirknerkle
04-05-2013, 11:12 PM
This is such a great project. Will you be publishing a how-to on this project with dimensions & drawings, etc.?

Strother85
04-05-2013, 11:34 PM
This is such a great project. Will you be publishing a how-to on this project with dimensions & drawings, etc.?

+1! Please do!

ErnieHorning
04-05-2013, 11:46 PM
I don’t think he can publish the plans because they’re something that he bought. I’m sure that he’ll tell you where he got the plans from though.

DanoNJ
04-06-2013, 03:03 PM
The plans are from Winfield Collections. I'm using them as a 'guide' and making some alterations as I go. For example, I'm planing on having 3 characters move up and down - not in the original plans.

Started painting the characters this week. I'll be posting pictures of them soon.

Thanks for the kind words!!!

DanoNJ
04-07-2013, 08:22 PM
Started painting the characters

timon
04-07-2013, 08:32 PM
Looking really good.

Dougp
04-07-2013, 09:27 PM
Started painting the characters

WOW, What a great job.

Donny M. Carter
04-07-2013, 09:39 PM
Looking good Dano! You've inspired me to change my display up a little this year! Thanks! :D

ErnieHorning
04-07-2013, 11:04 PM
Looking good Dano and coming along nicely.

JerryPlak
04-07-2013, 11:10 PM
Looking good Dano and coming along nicely.

Like he said :-) Looking good Dano

JasonPortwood
04-08-2013, 06:27 AM
I always wanted one of these but using blow molds instead. Is there a way to get power onto the carousel? I know I could use a rotating Christmas tree stand but I like this wood one and doubt a stand could rotate all that weight with the wood.

Jason

DanoNJ
04-08-2013, 10:35 AM
I always wanted one of these but using blow molds instead. Is there a way to get power onto the carousel? I know I could use a rotating Christmas tree stand but I like this wood one and doubt a stand could rotate all that weight with the wood.

Jason

What I will do is have a 'dumb' ribbon attached to the underside of the roof using the controller that came with the string to have the lights change color. To feed the power, I've ordered a slip ring which will be attached to a center post that remains stationary inside. Work on that will be completed in a few weeks and I'll be posting pictures of how that is done.

thanks everyone for the comments. Just as a side note, the painting in the pictures is by no means complete. Still need to do the outlining and shading.

tfischer
04-08-2013, 11:40 AM
You're making me look bad. I haven't even finished repairs from last year's display/tear-down yet. Heck, I finally got (mostly) everything stored away properly yesterday (other than said items that need repair)

tfischer
04-08-2013, 12:50 PM
Looking good Dano! You've inspired me to change my display up a little this year! Thanks! :D

This is why I was lamenting the lack of good prop-build threads in the thread I posted earlier today. A good prop-build thread like this usually inspires others to do something cool and creative themselves. Or at least directly copy said cool item ;) I personally dislike the trend that Christmas displays are taking to be more and more "lights only with abstract shapes".

Excellent work, Dano.

ben&bobbi
04-08-2013, 01:01 PM
Very cool. i have been pondering making one for the lighted reindeer wire frames, not sure how they will work, when you can see through them though. This might be enough motivation to get ready - for next year!

toozie21
04-08-2013, 01:17 PM
Awesome work (as usual) Dano! I'm gonna have to make a NJ trip this year to pay homage!

You aren't concerned about the weight of the display being turned by a wiper motor? I know you have it on the lazy susan, but I would be worried about the wind coming down my street and catching the figures like a kite (and the motor trying to fight through it)!

DanoNJ
04-08-2013, 03:10 PM
Awesome work (as usual) Dano! I'm gonna have to make a NJ trip this year to pay homage!

You aren't concerned about the weight of the display being turned by a wiper motor? I know you have it on the lazy susan, but I would be worried about the wind coming down my street and catching the figures like a kite (and the motor trying to fight through it)!
Thanks! As for the weight issue, so far so good. The the wind, well time will tell. Wont be the first time I chase down the street after a prop or need a re-build mid season. But that's how you learn.

toozie21
04-08-2013, 08:11 PM
Thanks! As for the weight issue, so far so good. The the wind, well time will tell. Wont be the first time I chase down the street after a prop or need a re-build mid season. But that's how you learn.

Yeah, I generally over-engineer while over thinking everything and either don't finish or make something that weighs 1000 pounds.

Did you work out the gears yourself, or use something like this template generator: http://woodgears.ca/gear_cutting/template.html

I am going to probably try to make some this year and it will be my first attempt.

timon
04-08-2013, 08:19 PM
What I will do is have a 'dumb' ribbon attached to the underside of the roof using the controller that came with the string to have the lights change color. To feed the power, I've ordered a slip ring which will be attached to a center post that remains stationary inside. Work on that will be completed in a few weeks and I'll be posting pictures of how that is done.

thanks everyone for the comments. Just as a side note, the painting in the pictures is by no means complete. Still need to do the outlining and shading.

This is where running 36 to 48V through the slip rings, safer than 120VAC, and then feed that into DC-DC supplies works great. Don't forget a extra large input cap to filter out slip-ring noise. For control wireless works wonders.

DanoNJ
04-08-2013, 09:24 PM
Yeah, I generally over-engineer while over thinking everything and either don't finish or make something that weighs 1000 pounds.

Did you work out the gears yourself, or use something like this template generator: http://woodgears.ca/gear_cutting/template.html

I am going to probably try to make some this year and it will be my first attempt.

Nice link!! I used the gears on the original plans.


This is where running 36 to 48V through the slip rings, safer than 120VAC, and then feed that into DC-DC supplies works great. Don't forget a extra large input cap to filter out slip-ring noise. For control wireless works wonders.

And that's why I'm using simple 12DCv ribbon. Since the ribbon has a controller with it, that will just be used - simple.

toozie21
04-09-2013, 05:58 AM
This is where running 36 to 48V through the slip rings, safer than 120VAC, and then feed that into DC-DC supplies works great. Don't forget a extra large input cap to filter out slip-ring noise. For control wireless works wonders.

Not to steal the message thread, but what is the concern about 120VAC safety versus 36-48V? Just curious.

DanoNJ
04-09-2013, 08:01 AM
just generally safer my guess.

timon
04-09-2013, 11:05 AM
It considerably safer. UL basically rates anything under 60VDC as non-hazardous and in fact will mainly look for physical hazardous items during testing. If you supply the 48VDC power supply its the only part that will be electrically tested and if it's already UL Listed they won't even do that.

There is more to it than this but you get the basic idea.

This is why I don't p.an for any 120VAC props where any ong can reach them. All 48VDC primary supplies would be well protected.

intwoit2002
04-09-2013, 10:14 PM
That is going to look amazing and the kids will enjoy it.

A couple of questions

Where and how will you store it?

Could you have used a Gilmer belt and pullys instead of making gears?

Not having access to the wood tools you have I was just thinking about an alternative.

Thanks,
Al

Looking forward to more pics.

DanoNJ
04-10-2013, 11:25 AM
Where and how will you store it?

Could you have used a Gilmer belt and pullys instead of making gears?

Not having access to the wood tools you have I was just thinking about an alternative.

Thanks,
Al

Looking forward to more pics.

Storage: All of my props are made to be disassembled for storage, this one will be a bit larger that most due to the floor and roof structure.
Yes, a belt drive would work also, however, I wanted to experiment with the wood gears.
As for the tools; used a circular saw, jig saw, miter saw drill. Not sure what alternatives you may use....

toozie21
04-10-2013, 11:27 AM
Just all around awesome! Would love to see some video Dan if you can get a chance to see why the links no longer work.

intwoit2002
04-10-2013, 01:19 PM
It looks great and very inspiring, not this year but maybe next for me. Love to see the finished show. Great job.
Al

DanoNJ
04-10-2013, 03:54 PM
Just all around awesome! Would love to see some video Dan if you can get a chance to see why the links no longer work.

Fixed all the links to YouTube above.

toozie21
04-11-2013, 07:37 AM
Perfect, thanks. Can't wait to see it running with the figures moving up/down!

DanoNJ
04-11-2013, 10:05 PM
More painting progress.

jklingert
04-11-2013, 10:22 PM
Looks great Dan!

Donny M. Carter
04-11-2013, 10:41 PM
Nice!

kwajtony
04-13-2013, 03:28 AM
This is an awesome job and a daunting task I am certain. I commend you on your craftsmanship. I am still working on my trees.

Onewish1
04-13-2013, 06:05 AM
looking great!!... I will put my request in now for a snowman :biggrin:

Jeff Millard
04-13-2013, 07:41 AM
It rained last night. Couldn't go anywhere because my windshield wiper motor is attached to a nice new prop at Dano's house...

Jeff

mschell
04-13-2013, 01:45 PM
it rained last night. Couldn't go anywhere because my windshield wiper motor is attached to a nice new prop at dano's house...

Jeff

lol!

JerryPlak
04-13-2013, 03:21 PM
Lol now we all know wear got it lol

Send from my Samsung using Taptalk 2

DanoNJ
04-13-2013, 07:06 PM
It rained last night. Couldn't go anywhere because my windshield wiper motor is attached to a nice new prop at Dano's house...

Jeff

Teach you to leave your truck unlocked!!

Jrd
04-17-2013, 04:21 PM
WOW this looks awesome! Looking forward to seeing more progress.

Matt_Edwards
04-17-2013, 05:36 PM
awesome is an understatement!
congrads on the inspiring build.

sent from one of those mobile thingies

DanoNJ
04-21-2013, 08:56 PM
Painted the roof.... getting there.

DanoNJ
04-21-2013, 09:01 PM
Some of the characters:

jklingert
04-21-2013, 09:22 PM
Dan, that looks more amazing every step of the way. I hope you bring it to the NJ Epic!

Onewish1
04-21-2013, 09:29 PM
love it!!

DanoNJ
04-28-2013, 06:17 PM
Update:

http://www.youtube.com/watch?v=51NwpeV_yKg&feature=youtu.be

Onewish1
04-28-2013, 07:11 PM
I am impressed.. great job!

timon
04-28-2013, 08:12 PM
Very, very nice. Might I make one suggestion. I'd look at finding a way to paint the back side of the riders. I thing it would look better while turning. I realize you'd have to come up with your own patters but it should be much simpler than the front.

Just a suggestion.

lightman
04-28-2013, 09:17 PM
Wow...very very cool! Great color scheme. Figures are perfect.

Terrific job.

I'll take 2 please....

Regards,
Lightman

Jrd
04-28-2013, 09:20 PM
Looks great! I agree with Timon though, painted backs would make it better.

mndless
04-28-2013, 10:42 PM
Really nice job !!!

kwajtony
04-29-2013, 03:35 AM
Looks great! I agree with Timon though, painted backs would make it better.

It certainly would make it look more finished.

DanoNJ
04-29-2013, 08:08 AM
Very, very nice. Might I make one suggestion. I'd look at finding a way to paint the back side of the riders. I thing it would look better while turning. I realize you'd have to come up with your own patters but it should be much simpler than the front.

Just a suggestion.
This is work in progress, gents.... If time permits, I will. If not I may paint black.

Donny M. Carter
04-29-2013, 08:58 AM
Looking good Dano!

Skunberg
04-29-2013, 04:05 PM
Great as is! Great job Dano!

timon
04-29-2013, 06:11 PM
If you don't have time then painting the back black definite will do the job nicely.

Matt_Edwards
04-29-2013, 07:20 PM
Wouldn't black be the best option anyway. That way the viewer is drawn to the main action.

sent from one of those mobile thingies

Donny M. Carter
04-29-2013, 07:30 PM
I think you should paint them pink!

DanoNJ
05-07-2013, 09:17 PM
RGB 'dumb' ribbon for the roof line. Now to install the slip ring.

http://www.youtube.com/watch?v=ezX-RAhE-wk&feature=youtu.be

DanoNJ
05-07-2013, 09:30 PM
Some pictures of the wording for the base / floor.

ErnieHorning
05-07-2013, 10:00 PM
Looks great Dan. Missed a dot though, just saying... :wink2:

jklingert
05-07-2013, 10:13 PM
Now to install the slip ring.
I thought carousels had Brass rings? :)

DanoNJ
05-07-2013, 10:39 PM
Looks great Dan. Missed a dot though, just saying... :wink2:

And thus my canned response. Bet you can't see it from your house.

Jack, mine is different, because it can be! :)

ErnieHorning
05-07-2013, 11:36 PM
It looks fine from here, no worse than your mug. :biggrin2:

DanoNJ
05-11-2013, 09:08 PM
Pictures of the slip ring installed

DanoNJ
05-11-2013, 09:11 PM
Well, I'm 90% completed, but a bit bummed. Looks like my trusty wiper motor isn't strong enough to lift the caracters up and down. The wieght of the plywood, especially all three, are just too heavy. So at this time, I'll settle for just round and round....

http://www.youtube.com/watch?v=ed0nvu4U2IY&list=UUtb3oMdiZlFT1SR7FbCnOCg&index=1

blickensderfer
05-11-2013, 09:28 PM
I can see you attaching more wiper motors one on each to lift them up and down.

DanoNJ
05-11-2013, 09:35 PM
I can see you attaching more wiper motors one on each to lift them up and down.

HA! Doubt it, I'm about done with this project. I still have a trolley to build!

Onewish1
05-11-2013, 09:48 PM
amazing job pal.. just love it

Jrd
05-11-2013, 10:42 PM
Looks awesome!

ErnieHorning
05-11-2013, 11:57 PM
Looks like my trusty wiper motor isn't strong enough to lift the caracters up and down. The wieght of the plywood, especially all three, are just too heavy.
Wait a minute. :hmm: Normally only two would be in exact sync with each other, the next two would be 1/3 behind and the next two would be 2/3 behind. If all of the characters weigh the same, everything should be in balanced. So if you added weight to match the heaviest one the motor should only have friction as the load.

DanoNJ
05-12-2013, 09:22 AM
Good point, Ernie, but only 3 move and the track below is not symetrical, so there goes that theory.

ErnieHorning
05-12-2013, 02:44 PM
... only 3 move and the track below is not symetrical ...
Rut Roh..., I guess you should used a starter motor. :rolleyes:

timon
05-12-2013, 04:24 PM
Can you add some springs to balance most of the weight. That should reduce the loading.

okshadow
07-03-2013, 12:34 AM
Looks great, I built mine last year, it's about 8' across, kept running into motor issues, what kind of motor did You run it on that will stay running over the long hall?

DanoNJ
07-03-2013, 03:06 PM
Looks great, I built mine last year, it's about 8' across, kept running into motor issues, what kind of motor did You run it on that will stay running over the long hall?

Wiper motor. I use them for almost all of my projects. Cheap, great tourque even at low voltage and a work horse.

okshadow
07-04-2013, 05:12 PM
Wiper motor. I use them for almost all of my projects. Cheap, great tourque even at low voltage and a work horse.

I had not thought of that motor, I used a garage door opener, not for running very long, tried a dryer motor, not enough to turn it, will find a wiper motor, any brand GM, Ford, Chrysler work any better.


http://www.youtube.com/watch?v=atOGB8ExZ-4&feature=player_embedded

okshadow
07-04-2013, 11:59 PM
Great idea, I went thru several motors which all failed from a dryer motor to a garage door opener.


http://www.youtube.com/watch?v=atOGB8ExZ-4&feature=player_embedded

DanoNJ
07-05-2013, 02:29 PM
Any brand will work well. Garage door openers are said not to be good for continuous use, from what I've heard. Nice display, btw!

Jeff Millard
07-05-2013, 06:17 PM
Wiper motor. I use them for almost all of my projects. Cheap,(I think he means free here) great tourque even at low voltage and a work horse.

Of course, cenote, Aproct and I can't drive any of our vehicles in the rain now that Dano has wiper motors for all his props...

Jeff

ErnieHorning
07-05-2013, 06:40 PM
Never park your car in front of Dano's house if it's going to rain.

Sent from my DROID RAZR using Tapatalk 2

okshadow
07-06-2013, 10:49 AM
Any brand will work well. Garage door openers are said not to be good for continuous use, from what I've heard. Nice display, btw!

A Garage door openers runs about 3-4 min and shuts down. now I am searching for that cheap/free wiper motor, thanks again for the idea.

ErnieHorning
07-06-2013, 12:29 PM
Do a Google search for Halloween, props and wiper motor. These guy use a lot of motors and know the ones that are the easiest to mount and how to modify them for different speeds and torque.

If you balance the load, it hardly requires any power to move things.

Sent from my DROID RAZR using Tapatalk 2

DanoNJ
07-06-2013, 07:05 PM
I go to the local jung yard. They have them on a shelf - no fuss.

Sent from my SCH-I200 using Tapatalk 4 Beta

okshadow
07-06-2013, 11:18 PM
Found a Ford pickup motor for $15.00.

ErnieHorning
07-06-2013, 11:27 PM
I’ve also seen them at local surplus stores. Good if you want them all the same. Plus you know that they’ve never wiped a window.