Category Archive: Creativity

DIY Felt Roller Build, Pt. 2 – The Bill of Materials

J. Matthew Phipps | July 6, 2014 | COMMENTS:2 Comments »

As promised, this is the “Bill of Materials” for the roller. The U.S. cost was a little over $400 (US). I tried to eliminate some of the prototyping costs from this list, for instance, my abortive attempt to use a sewing machine motor (hint: it worked fine, but then under load it began to smoke.) You’ll note, I did try to do a metric conversion, but then a looking at lumber discussion boards I began to realize that it is not as easy as just converting the numbers. If you have suggestions, please send me your input.

For builds in areas that aren’t 120 VAC 60 Hz, you’ll want to adjust your searches on Ebay, Amazon, or whatever you use locally for auctions and purchases. If where you live is like the U.S., then you probably have a neighbor who has a treadmill that they will let you have for free,  “if you will just please come and take it away” so their wives will stop bothering them about it.

I will post about the motor and controller box next.

Felt Roller Bill of Materials – Basic

Item (U.S.) Item (Metric) U.S. Supplier Unit Cost QTY U.S. Cost
115 VDC Treadmill Motor with Flywheel Ebay 35.00 1 35.00
MC 60 Treadmill Controller Ebay 25.00 1 25.00
Treadmill Motor Belt Ebay 7.00 1 7.00
Treadmill Front Roller Ebay 5.00 1 5.00
5K Potentiometer Amazon 1.25 1 1.25
Lumber 1x4x48 19x89x1200 Home Depot 4.00 9 36.00
Lumber: 2x2x30 38x38x705 Home Depot 2.66 4 10.64
Lumber: 1x2x30 19x38x705 Home Depot 1.75 4 7.00
Bolt 1/4-20 x 3 M6 76mm Home Depot 0.40 16 6.40
Bolt 1/4-20 x 1.5 M6 38mm Home Depot 0.38 5 1.90
Nuts 1/4 M6 Home Depot 0.40 21 8.40
Washers 1/4 M6 Home Depot 0.11 42 4.62
Fasteners 1/2 long (Box 50) Home Depot 7.00 1 7.00
Fasteners 3/4 long (Box 50) Home Depot 7.00 2 14.00
3/8 Bolt 6 Home Depot 3.40 6 20.40
3/8 threaded rod Home Depot 1.37 2 2.74
3/8 Tee Nut Home Depot 2.00 2 4.00
3/8 Nut (6 pack) Home Depot 0.20 7 1.40
4 PVC Pipe 10 foot Cut into 3 even pieces Home Depot 18.50 1 18.50
4 PVC Slip Cap Flat Home Depot 7.71 6 46.26
7/8 Washer Home Depot 1.20 48 57.60
Zinc Plated Corner Brace (4 pack) Home Depot 2.67 6 16.02
Zinc Plated Mending Plate (2 pack) Home Depot 2.49 1 2.49
3/8 Knob X2 (4 pack) Amazon 3.90 1 3.90
No Slip Feet (4 pack) Home Depot 3.00 1 3.00
Drip Pan Napa Auto Parts 22.50 1 22.50
Power Cord 9 foot Home Depot 15.00 1 15.00
Electrical Box Home Depot 20.00 1 20.00
Spa Timer Home Depot 20.00 1 20.00
Spyraflo Bearings BFM-375-B Amazon 5.50 6 33.00
#12 Bolts 2.5 inches Home Depot 0.22 16 3.47
#12 Nuts Home Depot 0.10 28 2.80
#12 Washers Home Depot 0.10 28 2.80
Category: Creativity, Tools TAG: ,

3 Day Felt & Straw Blocking Workshop

J. Matthew Phipps | May 27, 2014 | COMMENTS:No Comments »
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Just finished 3 days of a seminar with Wayne Wichern (http://www.waynewichernmillinery.com/) in Seattle. It was a fantastic weekend. Learned an incredible amount that has already boosted our skills.

I ended up blocking a really nice straw cloche, that was for Mary, and a military/stewardess inspired women’s hat, and finally a bowler out of fur felt for me.

I’m going to post pictures shortly.

I did get raves on the Hillbilly.
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Category: Creativity, Hats TAG: , , ,

Hillbilly Beginnings

J. Matthew Phipps | May 3, 2014 | COMMENTS:No Comments »
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This is the start of layout for my next hat project. My vision is for a floppy backwoods hillbilly hat.

I’m using this super rich sandalwood merino roving.

Sandalwood Merino

Laying the wool out on the resist, it’s almost ready for prefelt.

Layout Begins

Stay tuned as this comes together.

Category: Creativity, Felting, Hats TAG: , , ,

Inaugural Post

J. Matthew Phipps | October 22, 2013 | COMMENTS:No Comments »

Welcome aboard for the inaugural post for my Grey Falcon blog.

So, what is Grey Falcon Productions? GFP represents my creative side. Under the Grey Falcon label, I produce custom felt hats, build hat making and felting tools, write, and create computer programs.

J. Matthew Phipps

Category: Creativity