I worked most of the weekend getting the roller coaster car framework built. This was pretty simple as the work had already been done in the computer. I was supplied the size that the car needed to be already, and they would have spent a great deal of time on sizing it. When I was modelling it, I just used the dimensions supplied. With the computer model ready, and signed off on, I was able to extract the pieces I wanted from the model, and convert them to usable cut files in Aspire.
Once imported into Corel, this is what I had. Notice that the corner rads are faceted. I could have pulled the curves from Hexagon, and imported them as AI files, but the faceting would still be there.
So to get good clean vectors, I simply had to draw over the outline with new vectors. This allows me to get smooth rads on all the corners. And as the model was draw at real size in Hexagon, there is no worry that the sizing will be different.
I made the model with the side panels being 2.25" thick. Using the vector file I created, I was able to offset the shape inwards to give me my top curved thickener piece. For the long flat runs, I cut 3/4" MDF into 1.5" strips. The curved pieces would get 2 layers of 3/4" making up the 1.5" to work with the strips. The skins were 3/8" MDF to be strong, yet lighter than solid MDF would be. The whole thing is going to come apart so it can flat pack into the van for delivery.
When I lent my services to a collegue who was working on a film about 12 years ago, I was introduced to the world of cnc. I remember watching this huge machining centre milling out a slab of mdf and turning it into a fantastic set of gears. I knew that it would have taken me hours to achieve the same thing with traditional power tools. I decided then that I would invest in a cnc router for my own business Oxenham Design. At that time I could turn on a computer, but even to check email seemed like a crazy set of operations. I persevered and learned every piece of relevant software I could get my hands on. I am now fortunate enough to be using Vectric's ASPIRE software, and Techno cnc routers, which has helped us to create some amazing projects, both in part, or in full. I thought that this blog would be a great place to share "behind the scenes" adventures with the software, materials and equipment we use, as well as the projects we build.