Gen 2 Wooden Pickleball Paddle Template
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Gen 2 Wooden Pickleball Paddle Template
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I created a Gen 2 Wooden Pickleball Paddle Template. The intent of this design is have a template for creating original wooden pickleball paddles. From my research, I believe there were 2 or 3 original designs. This design was generated from one of the photos this link:
IRRC, the paddles used in the article above were loaned out the photograph(s). I grabbed an image of the paddle, transformed it in PS to make as orthogonal as possible, and then modeled it in FreeCAD. The Gen 2 Wooden Pickleball paddles have "buildup" on the handles for better fit, at least that is what the article above states, so I modeled them as well.
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Researching the type of wood used for the original paddles, it appears they settled on 3/8 inch marine grade plywood. I was not able to find this in the "Big Box" Stores in the US. But, I was able to source a 2ftx4ft sheet of 3/8 inch Baltic Birch marine grade plywood from a local lumber yard. One should be able to produce 9 paddles from a sheet this size. I created 3 paddles so far and used the following layout.
When 3D printing the template, I used Prusa Slicer ability to cut an STL with dovetails.
After tracing the paddle in the plywood, I used a jigsaw to rough cut the paddles out, a bandsaw for finer cuts, a powered 4 in. x 36 in. Belt and 6 in. disc sander to clean up the edges, and finally, hand sanded the edges to soften them.
I modeled the handles (AKA, "buildup") and super glued them to the handle before applying the overwrap. One of handles has small circular pocket where an RFID disc can be inserted. Why? Well if Joola can, then so can I ... ;-). There are many different type of RFID tags, and I happened to have extra round ones laying around.
Note, these paddles are not light. The paddle above made with 3/8 in Birch plywood weighs in at 380g. I did build a prototype with 1/2 in plywood from a Big Box store and it weighs in (yes, a bit lighter) at 366g.
My ultimate goal was to cut the paddles with CNC, it was going to take too long to setup, as I wanted to get a few paddles created quickly. I am now working on the CNC part of the process.