Richlite

Precise Spherical Voids via the Holdridge Radii Cutter Creating a perfect spherical void or a precise convex sphere on a lathe presents a unique mechanical challenge. Standard longitudinal and cross-feed movements are designed for cylindrical or tapered geometry, but they struggle with true arcs. Adam Savage demonstrates how to overcome this hurdle using a Holdridge Radii Cutter. This specialized tool utilizes a pivoting yoke to swing a cutting bit through a predetermined arc, allowing for the creation of hemispheres with mathematical accuracy. The core of the process lies in the relationship between the tool's pivot point and the cutting tip. To achieve a specific radius, you must set the distance from the center of the yoke to the tip of the tool bit. This requires meticulous measurement and a solid understanding of your lathe's centerline. While the tool itself is a masterpiece of vintage engineering, the setup—specifically centering the cutter on the workpiece—is where most builders falter. Tools and Materials for Precision Machining To replicate these results, you need a robust lathe and specific measuring equipment. Adam Savage utilizes Richlite, a dense paper-based phenolic resin, for the initial test void, and Delrin for the heavy-duty camera receiver. * **Holdridge Radii Cutter**: The primary tool for swinging the arc. * **Gauge Blocks**: Essential for setting the precise radius distance between the cutter spindle and the tool bit. * **Four-Jaw Chuck**: Necessary for holding large, irregular, or heavy stock like the 6-inch Delrin block. * **Digital Readout (DRO)**: Highly recommended for tracking the cross-slide and carriage positions during the centering process. * **Ringing Supplies**: Clean surfaces and a steady hand to "ring" gauge blocks together for maximum accuracy. Dialing in the Setup with Gauge Blocks Setting the radius is a game of subtraction and stacking. On the Holdridge Radii Cutter, the center of the spindle is exactly 0.5 inches behind the milled flats. If you want to cut a 3.5-inch diameter (a 1.75-inch radius), you don't just set the blocks to 1.75. You must account for that 0.5-inch offset. Subtract the 0.5-inch spindle offset from your target radius. For a 1.75-inch radius, you need a gauge block stack of exactly 1.25 inches. Place this stack against the milled flat and adjust the tool bit until it kisses the block. This ensures the tip of your cutter is exactly at the desired radius from the pivot point. **Ringing** the blocks together—sliding them against each other under pressure until they stick—is vital to eliminate any air gaps or debris that could throw off the measurement by several thousandths of an inch. Centering and Executing the Sweep Once the tool is set, the most critical step is aligning the pivot point of the Holdridge Radii Cutter with the centerline of the lathe. Adam Savage reveals a practical trick: bring the cutter to the face of the workpiece and use the tool's own radius setting to find the center. If your tool is set for a specific radius, marrying that tip to the edge of the diameter you intend to cut will naturally place the pivot point on center. Engage the sweep by rotating the handle manually. For materials like Richlite or Delrin, keep the RPM moderate and take steady, sweeping passes. Avoid aggressive depths of cut, as the yoke can flex under high load, resulting in a distorted sphere. The goal is a smooth, continuous motion that allows the bit to peel away material in a perfect arc. Troubleshooting the Perfect Arc If you notice a "nub" or a small artifact at the center of your void, your tool is likely slightly off-center. Even a few thousandths of an inch of misalignment will leave a physical signature at the pole of the hemisphere. To fix this, adjust your cross-slide incrementally and take a light finishing pass. Surface finish issues in composite materials like Richlite often stem from heat or dull bits. If the material looks "scraped" rather than cut, check your tool's sharpness and consider a slower feed rate. When working with large stock like the 6-inch Delrin used for the 150mm ball head receiver, ensure your chuck jaws are reversed and tightened securely. Large diameter plastic can exert significant centrifugal force, and any vibration will ruin the precision of the radius. Professional Results for Custom Hardware The final result of this process is a high-performance receiver capable of holding heavy cinema gear. By successfully machining a 150mm ball head mount out of Delrin, you create a customized, ultra-stable platform for equipment like the Arri 35mm camera. This method provides a level of fit and finish that off-the-shelf components rarely match, proving that vintage tools like the Holdridge Radii Cutter remain indispensable in the modern workshop.