John Gifford

Project by

John Gifford

General Information

Yet another iPhone dock.

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Material Description Price
End Mill Sample Pack, 1/8 in Shank

End Mill Sample Pack, 1/8 in Shank

Quantity: 5 (mix of 3 different types), Shank Diameter: 1/8 in, Cutting Diameter: 1/8 in, Type: End Mills, Cutting Length: Varies, Overall Length: Varies, Cutting Material 1: Linoleum, Cutting Material 2: Wood, Cutting Material 3: Soft Metals, Cutting Material 4: Linoleum, Cutting Material 5: Aluminum, Bit Packs: Variety Packs

1

Gather materials

Wood

1 – 5.5″ × 8.5″ × 3/4" Solid Wood (alder, pine, walnut, cherry, etc.)
1 – 8.5″ × 11.25″ × 1/2" Baltic Birch Plywood
1 – 1/4" (min 1″ × 2.5″) Solid Wood

Tools and Other

X-Carve of course
Pencil
Glue
Sander
Sandpaper
Bandsaw

2

Cut Outside Pieces

From the 3/4" solid wood.

Easel Files – Outside Pieces

3

Cut Inside Pieces

From the 1/2" plywood.

Easel Files – Inside Pieces

I cut this in two steps. First using a 1/8" bit cut the outline profiles. After that is finished, I switched to a 1/16" bit and cut the recesses for the middle channel for the Lightning cable.

4

Glue it together and sand

Glue outside pieces on the outside, of course.
Glue the two inside pieces with the cable channels together and the other

I used a spindle sander and a random orbit sander to get the job done.

One note on all 4 inside pieces, there’s a slot for the piece of wood that the phone rests on. I used my band saw to make this a little deeper and square the inside corners a bit. The easel files could certainly be updated, but I haven’t taken the time to do that yet.

5

Cut the Phone Rest

Cut and shape so it fits into the middle slot.

You’ll also what to drill a hole that follows the cable channel in the bottom of the base. I used a 1/2" bit so the end of the lightning cable would fit through.

6

Stain and Finish

I just used General Finish Salad Bowl Finish, but you can stain and finish to your liking.

Patrick Brown
This is cool are you sharing the files for others to make your design?
Patrick Brown
John Gifford
Hey Patrick, the easel links are in the instructions, steps 2 & 3, are you not able to access them?
John Gifford
Ray Barnett
Hey John, I like your dock design but when I clicked the link it says that the design was not shared publicly. Any idea as to why it's not working?
Ray Barnett
John Gifford
Hey there, sorry it took so long for me to update these links. They should be shared public now, let me know if you're still having trouble accessing them.
John Gifford
Gary Martin
I just got my carvey. What bit did you use? I just have the one standard 1/16 the comes with it. It isn't long enough to go through the 3/4 inch wood. Suggestions?
Gary Martin
John Gifford
Gary, I would suggest getting a 1/8 straight flute bit. If that's not an option you could go with thinner material, you'd just need to use more layers. But a 1/16 bit is really too small to carve this piece, I would't recommend it.
John Gifford
Gary Martin
Thanks John, I have another question. One of my students in class wants to make this. When we go to do the middle pieces we can only print 2 due to smaller space on the Carvey.We had to delete and rotate the other 2. It warned us that it could not carve with the current settings. Any ideas?
Gary Martin