I found some old Popular Mechanics type plans on the net, adapted them a bit and hit the shop. The motor/flex shaft is from an old (at least 50 years old) Montgomery Wards scroll saw and accessory set that belonged to my late Grandfather. I already had the V-block and split point cutting tools. I bought the nylon washers and short section of threaded plastic rod & coupling nut for the tracing stylus for about $5.00 at the local hardware store. Everything else was workshop scraps.
The ratio is adjustable (2:1, 3:1, 4:1) and I made my template by printing a large font on the printer and tracing it by hand the first time. The minor squiggly errors became less perceptible with each reduction and are not noticeable at all in the final product.
Eventually, I’ll buy a real one primarily so I can use a self-centering vise and real templates, but for now this one is doing fine.
I have the plans (pdf format), but no place to host them. If anyone is interested in building one of these contraptions, send me a pm and I’ll share the plans via email.
