The All New Glass Bottle Cutting and Sanding Machine from What’s New Johnny? This is just one more great labor-saving device from Johnny. Please enjoy this video.
Let’s get started
The bottle is held by the neck using a special designed drive shaft held in place by a pillow block bearing, and featuring a glass filled nylon nose that fits the inside diameter of the bottle neck. The drive shaft is rotated by a common rotisserie motor. This assembly is adjustable to compensate for bottle length. The platform is made up of 2 pcs of 3/4” plywood with threaded inserts (1/4”-20 internal thread), spaced 1” apart. This allows for bottle length adjustment. I can cut bottles up to 6” diameter and 18” in length. The blue bottle that’s mounted is 13” long and 3” in diameter. The photo shows a variety of bottles I’ll cut in upcoming videos titled “Bottle Cutting and Sanding” 1,2,3 and 4 available to view at www.WhatsNewJohnny.com
The setup
Notice that the fat end of the bottle is cradled by 2 soft wheels. This supports the bottle and allows it to rotate during the actual cutting process. The support is adjustable up and down to fit the bottle diameter. The bottle is held in place by a special rubber band that rotates with the bottle allowing the operator to concentrate on the cutting function.
Safety
When preparing to cut a bottle its important to place the plexiglass child in the proper location. Cutting glass debree and fine dust will be collected by a special pickup tube designed to plug in your shop vac. It is still necessary to wear safety glasses, gloves, ear plugs and face mask to protect from any residual degree and dust
Let’s cut a bottle. I try to do bottle-cutting outside with the breeze at my back.
The Bottle is cut while it slowly rotates in a clockwise direction. I’m using a green diamond glass cutting disc amounted on Makita 4 1/2” Angle Grinder. The angle grinder is attached to a special bracket allowing the necessary movement to cut the bottle.
As the bottle rotates I advance the cutting wheel until it penetrates the bottle and I hold the cutter in that position until the bottle bottom is cut and the second rotation to clean up the cut edge is complete. This takes about one minute. Notice the piece of wood placed to catch the bottom.
When done carefully remove the rubber band, disconnect the bottle from the driver, empty the debris that’s inside the bottle, and store it.
I try to do bottle cutting and sanding outside with the breeze at my back
Now it’s time to sand the cut bottle
The rolling cart has a glass bottle sanding platform mounted on the end. It is closer to the ground and away from your face by design. Notice that the sanding platform has a special pickup tube for your shop vac. The cart The Bauer sanding device, mounted under the platform, turns the sanding disk at the required speed of 650 rpm.
We use a special Aluminum Oxide hook and loop sanding disc which lasts for about 10 bottles. These discs are available from www.WhatsNewJohnny.com.
Sanding Safety
Cutting glass debris and fine dust will be collected by a special pickup tube designed to plug in your shop vac. It is still necessary to wear safety glasses, gloves, ear plugs, and a face mask to protect from any residual degree and dust.
The cart
I mounted the machine on a heavy rolling cart with drawers for cutting and sanding supplies. This makes it easy to store in a shop and supports the sanding platform.
The cedar dividers at the bottom of the cart will help you organize the bottles. To complete the project I mounted a power strip on the end of the cart.
This build represents over one year of trial and error – engineering revisions. Although I think it’s a very useful machine, I’m open to suggestions.
This is the “Perfect DIY Project”
It’s very easy to build by following the complete plans including detailed illustrations, color photos, a resource list, the cost for each item, and a complete assembly/disassembly video. The time to build is about 30 hours using simple hand tools although I used a bench-top table saw, drill press, and angle grinder. All together I spent about 30 hours and $500 on this project. As you’ll see on the resource list Harbor Freight, Home Depot and Amazon are my main sources.
Stop spoiling your favorite bottles. Now you can spend more time on your creative work.
“If you’re going to make It, make it nice”
The plans will be available soon at What’s New Johnny.
Now we’re going to start cutting bottles grouped by length and diameter. I’ll show you how to adjust each bottle’s diameter and length. During the actual cutting, the cutter, as well as the shop vac, prohibits audio but during each setup, I’ll share what I’ve learned about bottle cutting.
4 different Videos will cover the 14 bottles. I think I’ll title them “Bottle Cutting and Sanding” 1,2,3 and 4. They will be linked together so you can watch them all.