In an incredible amount of detail, Gord has written up and photographed the whole process:

http://gordsgarage.wordpress.com/2011/11/21/the-full-monty-part-1/

http://gordsgarage.wordpress.com/2011/11/22/the-full-monty-part-2/

In summary, it went from this mill finish:

To this polished finish:

To this anodized finish:

Amazing!

Like it?

The problem is, squeezing enough limes for a party of 60+ people takes a lot of time (and limes).  After about the fifth lime the first time… I had enough!

I went down to the shop and built a simple but powerful hinged wooden squeezer about 3′ long.  It looked like two canoe oars with a hinge holding them together.  With this contraption, a suitable helper (Eli), and a big stainless steel bowl, we could really crank out the lime juice (gallons).

Since using that a number of times, I’ve thought of some improvements I’d like to make, eventually ending in a fabricated stainless steel mechanism that is easy to use, powerful, and helpful.  The force applied to the lime should be compounded at the end of the squeeze cycle, taking full advantage of maximum leverage to get the last drops out (less waste, less fatigue).

Using the power of four-bars, I’m working up a Solid Works model which should meet most of the above criteria.  I think we will soon build a prototype out of maple, which is a very hard wood.

Here is a picture of it “open”:

Here is a picture of it “Closed”:

The little metal guys normally stand at attention in rows — millions of them (molecules).  When you heat them up red hot, they start dancing and get all mixed up and out of order; not in rows any more.  When you cool them down, they get back into nice neat rows.

However, when you cool them off really fast by dipping in cold water, they get frozen before they can get back into nice neat rows!

If the metal guys are in nice neat rows, and you push on a row really hard, they can all move sideways.  But if they are all mixed up, it’s hard for them to move any way.  

This makes the metal really hard.

As part of Ezra’s box project, he needed to countersink the nails into the plywood.  I should have one, but I don’t have a countersink handy that would do the trick.

So we made one!

1/4″ diameter W1 tool steel rod (water hardened) was cut down to about 3.5 inches long.  Being that I don’t have a metal lathe, I improvised by chucking the metal into my drill and grinding it on the grinder – while spinning.  This resulted in a fairly uniform (albiet scratched) conical point.   We wire brushed it a bit on the grinder to smooth it out, and then took it over to the other side of the shop for heat treatment.

This casual approach to tempering worked well for our purposes.  We heated the metal red hot (just the end) and dunked it in cold water.  Then we polished it up a little bit.

In informal tests, this made it REALLY hard.  If I placed a nail against the top end and banged it, it would scratch the punch.  If I placed a nail agains the bottom (hard) end and banged it, it would flatten the nail without even marking the surface of the punch.

Also, the punch would reliably put small holes in a cast-iron vice and other metal without any noticeable deformation.  Nice!

Here is the pictures:

(Fire extinguisher was about 2 feet to the left, in case you were wondering!)

Here is a photograph of the finished portfolio in a 5″ binder printed on 48lb double sided matte photo paper.  It is really neat to look at and remember everything we did this year.

I must say, it’s looking pretty nice!  It is rather amazing to look back at the year, and see in detail what was going on with Eli.

One of my favorites is on page 159 (read the letter on the telephone pole):

Here is a screen shot of the book view:

The software has many improvements from the last couple days alone.  A background page renderer runs at all times, and will re-render a book’s page if anything on it changed.  The user interface for positioning images on a page is nearly complete.  I’ve enhanced the database with storage of full size JPEG images as well as info about the image (width, height, type, size).

Here is a screen shot of the page editor:

1. Look cool
2. Be inexpensive to build
3. Be safe
4. Comfortable!
5. Fun

Here is an example page render without the photographs included.  Still need a UI for selecting photographs and positioning them on the white area of the page.

At the bottom, see an ImageMagick Text Example about the python code used to render multiple text areas and color blocks on one image…

It took me a long time to figure out how to use ImageMagick to place multiple text areas on one image.  Here are some keywords for google:

ImageMagick, ImageMagick multiple text areas, ImageMagick pdf rendering, ImageMagick text.

      PrimerFont = join(App.Path, 'Static', 'Primerb.ttf')
      PrimerFontBold = join(App.Path, 'Static', 'Primer.ttf')
      RenderFile = join(TempDir, 'Render.jpg')

      # Build the full image
      subprocess.check_call((
        '/usr/bin/convert',

        # Setup the background
        '-size', '2550x3300',
        'xc:white',

        # Title Bar
        '-fill', 'grey14', '-draw', 'rectangle 0,0 2550,300',

        # Summary bar
        '-fill', 'RoyalBlue4', '-draw', 'rectangle 0,300 2550,600',

        # Description Bar
        '-fill', 'LightGrey', '-draw', 'rectangle 0,600 2550,1050',

        # Now draw the Name
        '(',
          '-density'    , '300',
          '-fill'       , 'white',
          '-background' , 'grey14',
          '-font'       , PrimerFont,
          '-size'       , '1650x150',
          '-gravity'    , 'West',
          '-pointsize'  , '20',
          'caption:'    + self.Book.Name,
        ')',
        '-gravity', 'NorthWest', '-geometry', '+150+150', '-composite',

        # Now draw the Date
        '(',
          '-density'    , '300',
          '-fill'       , 'white',
          '-background' , 'grey14',
          '-font'       , PrimerFont,
          '-size'       , '600x150',
          '-gravity'    , 'East',
          '-pointsize'  , '20',
          'caption:' + Activity.Date.strftime('%B %d, %Y'),
        ')',
        '-gravity', 'NorthEast', '-geometry', '+150+150', '-composite',

        # Now draw the Summary
        '(',
          '-density'    , '300',
          '-fill'       , 'white',
          '-background' , 'RoyalBlue4',
          '-font'       , PrimerFontBold,
          '-size'       , '2250x300',
          '-gravity'    , 'Center',
          '-pointsize'  , '20',
          'caption:'    + Activity.Summary.replace("\n", " "),
        ')',
        '-gravity', 'North', '-geometry', '+0+300', '-composite',

        # Now draw the Description
        '(',
          '-density'    , '300',
          '-fill'       , 'black',
          '-background' , 'LightGrey',
          '-font'       , PrimerFont,
          '-size'       , '2250x450',
          '-gravity'    , 'Center',
          '-pointsize'  , '14',
          'caption:'    + Activity.Description.replace("\n", "\\n"),
        ')',
        '-gravity', 'North', '-geometry', '+0+600', '-composite',

        # Now draw the Page
        '(',
          '-density'    , '300',
          '-fill'       , 'black',
          '-background' , 'white',
          '-font'       , PrimerFont,
          '-size'       , '2250x150',  #entire right half minus 150pt margin
          '-gravity'    , 'Center',
          '-pointsize'  , '14',
          'caption:'    + 'Page {0}'.format(self.PageNumber),
        ')',
        '-gravity', 'South', '-geometry', '+0+150', '-composite',

#        NameFile, '-geometry', '+0+0', '-composite',
#        DateFile, '-geometry', '+1275+0', '-composite',
#        SummaryFile, '-geometry', '+0+150', '-composite',
#        DescriptionFile, '-geometry', '+0+450', '-composite',

        RenderFile,
        ))