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	<title>Syzygy ... &#187; Projects</title>
	<atom:link href="http://syzygypens.com/blog/category/woodturning/projects/feed/" rel="self" type="application/rss+xml" />
	<link>http://syzygypens.com/blog</link>
	<description>... adventures in woodturning and woodworking</description>
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		<title>Turn a wooden mallet with an oval handle</title>
		<link>http://syzygypens.com/blog/2009/07/27/turn-a-wooden-mallet-with-an-oval-handle/</link>
		<comments>http://syzygypens.com/blog/2009/07/27/turn-a-wooden-mallet-with-an-oval-handle/#comments</comments>
		<pubDate>Mon, 27 Jul 2009 11:15:50 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=962</guid>
		<description><![CDATA[<p>A wooden mallet is very useful in the workshop and I&#8217;ve been meaning to make one for a while.   To make things a bit more interesting I decided to make one with an oval handle using off center turning.  An oval handle is also more comfortable to hold than a circular handle.  I made [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/09/15/if-the-only-tool-you-have-is-a-hammer/' rel='bookmark' title='Permanent Link: If the only tool you have is a hammer &#8230;'>If the only tool you have is a hammer &#8230;</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Three'>Making a Tool Handle &#8211; Part Three</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p>A wooden mallet is very useful in the workshop and I&#8217;ve been meaning to make one for a while.   To make things a bit more interesting I decided to make one with an oval handle using off center turning.  An oval handle is also more comfortable to hold than a circular handle.  I made this from cherry, probably not the best of woods to use as it is not the hardest of hardwoods, but it is what I had on hand at the time.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_836113.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-975" title="ACT_836113" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_836113-300x201.jpg" alt="ACT_836113" width="300" height="201" /></a></p>
<p><span id="more-962"></span>To make the head of the mallet I started with a piece of cherry just over 3&#8243; square and about 4&#8243; long.  I turned it round between centers, turned a small tenon on one end and then mounted it in my chuck jaws.  After re-truing it I turned a slight taper from the headstock side to the tailstock side.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_834901.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-963" title="ACT_834901" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_834901-300x201.jpg" alt="ACT_834901" width="300" height="201" /></a></p>
<p>I then drilled a 7/8&#8243; hole in the tailstock side, about 2 1/2&#8243; deep using a forstner bit.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835103.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-965" title="ACT_835103" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835103-300x201.jpg" alt="ACT_835103" width="300" height="201" /></a></p>
<p>I mounted a scrap piece of wood in my chuck and turned a tenon to match the 7/8&#8243; hole I had drilled in the mallet head.  I mounted the mallet on the tenon, brought the tail stock up and turned most of the end of the mallet head concave.  After moving the tail stock I removed the last bit of the nub.  I turned this side concave as I wanted to be able to stand the finished mallet on end with the handle up.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835204.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-966" title="ACT_835204" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835204-300x201.jpg" alt="ACT_835204" width="300" height="201" /></a></p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835305.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-967" title="ACT_835305" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835305-300x201.jpg" alt="ACT_835305" width="300" height="201" /></a></p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835406.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-968" title="ACT_835406" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835406-300x201.jpg" alt="ACT_835406" width="300" height="201" /></a></p>
<p>For the handle I used a piece just over 1 1/2&#8243; square by about 12&#8243; long.  I measured the handle of one of my other hammers that was comfortable to use and found the maximum dimensions where 1 1/2&#8243; by 1 1/8&#8243;.  I found the center of each end of the piece that was to be my handle and marked it.  I also marked a point 3/16&#8243; either side of the center point.  I calculated the 3/16&#8243; as follows:  1 1/2&#8243; minus 1 1/8&#8243;  equals 3/8&#8243; (the difference between the long and short dimensions of the oval), therefore my offset needed to be half of that.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/Drawing1.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-976" title="Drawing1" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/Drawing1-300x256.jpg" alt="Drawing1" width="300" height="256" /></a></p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835507.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-969" title="ACT_835507" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835507-300x201.jpg" alt="ACT_835507" width="300" height="201" /></a></p>
<p>I mounted the piece between centers and turned it to 1 1/2&#8243; round.  Then I moved the piece towards the tool rest by 3/16&#8243; using the offset marks on each end.  I double checked the piece would rotate with out hitting the tool rest and then turned the piece so that it measured 1 5/16&#8243; on the narrow side.   I took my time with this as I did not need to remove much wood and I was also turning a fair amount of air.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/Drawing2.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-977" title="Drawing2" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/Drawing2-300x256.jpg" alt="Drawing2" width="300" height="256" /></a><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835709.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-971" title="ACT_835709" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835709-300x201.jpg" alt="ACT_835709" width="300" height="201" /></a></p>
<p>I then moved the piece away from the tool rest and aligned it on the other marks offset 3/16&#8243; from the center.  After checking the piece could rotate freely I carefully turned it down so that it measured 1 1/8&#8243; on the narrow side.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/Drawing3.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-978" title="Drawing3" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/Drawing3-300x256.jpg" alt="Drawing3" width="300" height="256" /></a></p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835810.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-972" title="ACT_835810" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835810-300x201.jpg" alt="ACT_835810" width="300" height="201" /></a></p>
<p>Now that I had established the maximum dimensions of the handle, I turned a profile on it that gave me a nice hand hold.  I did this using the two offset marks in turn, again proceeding slowly and taking care not to touch the last 2 1/2&#8243; close to the head stock.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835911.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-973" title="ACT_835911" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_835911-300x201.jpg" alt="ACT_835911" width="300" height="201" /></a></p>
<p>Finally I mounted the piece on the center marks, turned the first 2 1/2&#8243; down to 7/8&#8243; so that it would make a snug fit in the mallet head, and finished the end of the handle before parting it off.  I then glued the handle in the mallet head and once the glue had dried applied a coat of wax to the mallet.</p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_836012.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-974" title="ACT_836012" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_836012-300x201.jpg" alt="ACT_836012" width="300" height="201" /></a></p>
<p><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_836113.JPG" rel="lightbox[962]"><img class="aligncenter size-medium wp-image-975" title="ACT_836113" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_836113-300x201.jpg" alt="ACT_836113" width="300" height="201" /></a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/09/15/if-the-only-tool-you-have-is-a-hammer/' rel='bookmark' title='Permanent Link: If the only tool you have is a hammer &#8230;'>If the only tool you have is a hammer &#8230;</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Three'>Making a Tool Handle &#8211; Part Three</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
</ol></p>]]></content:encoded>
			<wfw:commentRss>http://syzygypens.com/blog/2009/07/27/turn-a-wooden-mallet-with-an-oval-handle/feed/</wfw:commentRss>
		<slash:comments>4</slash:comments>
		</item>
		<item>
		<title>Making a Board Game on the lathe</title>
		<link>http://syzygypens.com/blog/2009/07/26/making-a-board-game-on-the-lathe/</link>
		<comments>http://syzygypens.com/blog/2009/07/26/making-a-board-game-on-the-lathe/#comments</comments>
		<pubDate>Sun, 26 Jul 2009 05:48:26 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=935</guid>
		<description><![CDATA[<p align="left">In a recent post I mentioned I had made a Quarto Board Game for a friend of mine.  It is made from walnut and oak that he sent me.  It was a fun project and was done almost entirely on the lathe.  I used a table saw to cut the stave sections for [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
<li><a href='http://syzygypens.com/blog/2009/07/16/quartro-board-game/' rel='bookmark' title='Permanent Link: Quarto Board Game'>Quarto Board Game</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p align="left">In a recent post I mentioned I had made a <a href="http://syzygypens.com/blog/2009/07/16/quartro-board-game/" target="_blank">Quarto Board Game</a> for a friend of mine.  It is made from walnut and oak that he sent me.  It was a fun project and was done almost entirely on the lathe.  I used a table saw to cut the stave sections for the sides of the box, and a drill press for the inlays on the top.</p>
<p align="left">This is an article on how I made the board game.  The techniques here could be adapted for a number of different games.  You can download a copy of the rules for Quarto <a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/Quarto Rules.pdf" target="_blank">here</a>.</p>
<p align="center">
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_8285561.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_828556" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_828556_thumb1.jpg" border="0" alt="ACT_828556" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_8284551.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_828455" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_828455_thumb1.jpg" border="0" alt="ACT_828455" width="244" height="165" /></a></p>
<p><span id="more-935"></span></p>
<p align="left">This is the wood that I received from him.  The first step was to mark out how I was going to use the  pieces and to calculate the size of the pieces I needed for the stave construction of the sides of the box.  I used a <a href="http://www.woodturnersresource.com/extras/projects/Segments.exe" target="_blank">program</a> I downloaded from  <a href="http://www.woodturnersresource.com/tpt/" target="_blank">Tutorials, Projects &amp; Tips</a> section of <a href="http://www.woodturnersresource.com/" target="_blank">Woodturner’s Resource</a>.</p>
<p align="center">
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816101.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_816101" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816101_thumb.jpg" border="0" alt="ACT_816101" width="244" height="165" /></a></p>
<p align="left">After milling some of the oak pieces using my jointer and planer, I set the angle of my table saw blade using my <a href="http://www.rockler.com/product.cfm?page=17206&amp;sid=AFV82 " target="_blank">Wixley Digital Angle Gauge</a>.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816202.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_816202" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816202_thumb.jpg" border="0" alt="ACT_816202" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816404.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_816404" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816404_thumb.jpg" border="0" alt="ACT_816404" width="244" height="165" /></a></p>
<p align="left">The next step was to cut them to length.  I use a <a href="http://www.rockler.com/product.cfm?page=17821&amp;sid=AFV82 " target="_blank">fence clamp</a> and a scrap block of wood to offset the table saw fence so that the pieces do not get trapped between the blade and fence as I am crosscutting them.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816505.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_816505" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816505_thumb.jpg" border="0" alt="ACT_816505" width="244" height="165" /></a></p>
<p align="left">The last piece is cut using a stop block on my crosscut sled as it was to short to hold safely any other way.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816707.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_816707" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816707_thumb.jpg" border="0" alt="ACT_816707" width="244" height="165" /></a></p>
<p align="left">A dry test fit to check that all the joints were nice and tight.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816808.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_816808" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_816808_thumb.jpg" border="0" alt="ACT_816808" width="244" height="165" /></a></p>
<p align="left">I then laid the pieces flat, end to end, and placed a strip of clear packing tape over them.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817111.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817111" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817111_thumb.jpg" border="0" alt="ACT_817111" width="244" height="165" /></a></p>
<p align="left">Then I flipped it over so the packing tape was on the bottom, applied glue to all the joints, rolled the tube up and clamped it using a couple of <a href="http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/merle_clamp.html" target="_blank">Merle clamps</a>.  These are awesome clamps for this sort of work, they have flexible jaw inserts and the banding is steel.  You can also get extra jaw inserts and add as necessary depending on how many corners the piece you are clamping has.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817212.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817212" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817212_thumb.jpg" border="0" alt="ACT_817212" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817313.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817313" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817313_thumb.jpg" border="0" alt="ACT_817313" width="244" height="165" /></a></p>
<p align="left">Once the glue was dry I turned a groove in a piece of 3/4” plywood so that the piece fitted snugly in the groove, centering it on the lathe.  The plywood is attached to the lathe with a scrap peice of wood that had been turned true and tapped using my <a href="http://www.woodcraft.com/AffiliateWiz/aw.aspx?A=223&amp;Task=Click&amp;targetURL=http://www.woodcraft.com/family.aspx?familyid=20109" target="_blank">Beall Spindle Tap</a>.  The piece was glued to the plywood.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817414.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817414" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817414_thumb.jpg" border="0" alt="ACT_817414" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817616.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817616" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817616_thumb.jpg" border="0" alt="ACT_817616" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817717.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817717" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817717_thumb.jpg" border="0" alt="ACT_817717" width="244" height="165" /></a></p>
<p align="left">I then trued the piece on both the outside and inside and cut a shallow groove into which the lid of the box would be glued.  I also parted the box sides off.  I did not part all the way through using my parting tool.  I finished the parting cut off with the lathe off using a hand saw.  Note:  don’t discard the section that is left still attached to the plywood!!  This will be used later.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818222.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818222" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818222_thumb.jpg" border="0" alt="ACT_818222" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818424.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818424" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818424_thumb.jpg" border="0" alt="ACT_818424" width="244" height="165" /></a></p>
<p align="left">Using my band saw I cut both the top and bottom walnut pieces round.  I mounted the piece that was to be the bottom of the box on the lathe, turned it true and turned a tenon on one side.  This side would be the outside of the box.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817818.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817818" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817818_thumb.jpg" border="0" alt="ACT_817818" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817919.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_817919" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_817919_thumb.jpg" border="0" alt="ACT_817919" width="244" height="165" /></a></p>
<p align="left">I turned the piece around and flattened the side and turned a recess in it that matched the groove turned in the box side.  As this side would be the inside of the box I sanded it at this point.  Once it was glued to the sides of the box it would be difficult to sand it.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818020.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818020" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818020_thumb.jpg" border="0" alt="ACT_818020" width="244" height="165" /></a></p>
<p align="center">
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818323.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818323" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818323_thumb.jpg" border="0" alt="ACT_818323" width="244" height="165" /></a></p>
<p align="left">The bottom piece was then glued to the sides of the box.</p>
<p align="center">
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818525.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818525" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818525_thumb.jpg" border="0" alt="ACT_818525" width="244" height="165" /></a></p>
<p align="left">Once the glue was dry it was put back on the lathe by mounting the tenon on the bottom in my chuck.  A groove was then cut in the box side where the top piece would be glued in.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818626.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818626" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818626_thumb.jpg" border="0" alt="ACT_818626" width="244" height="165" /></a></p>
<p align="left">The piece of walnut that was to be the box top was then mounted on another chuck, put on the lathe and trued up.  The side towards the tailstock would be on the inside of the box so it was turned flat and sanded.  A recess was cut that was a snug fit to the groove turned on the box sides.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818727.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818727" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818727_thumb.jpg" border="0" alt="ACT_818727" width="244" height="165" /></a></p>
<p align="left">The top was then glued to the box sides.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818828.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818828" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818828_thumb.jpg" border="0" alt="ACT_818828" width="244" height="165" /></a></p>
<p align="left">Once the glue was dry I attached the chuck back on the lathe, brought the tail stock and parted the lid off.  Once again, I did not part all the way through using my parting tool.  I finished the parting cut off with the lathe off using a hand saw.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818929.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_818929" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_818929_thumb.jpg" border="0" alt="ACT_818929" width="244" height="165" /></a></p>
<p align="left">The lid was then mounted in a chuck and a recess turned.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819030.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819030" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819030_thumb.jpg" border="0" alt="ACT_819030" width="244" height="165" /></a></p>
<p align="left">Then the base of the box was mounted in a chuck and a groove turned so that the lid was a snug fit.  The second picture shows the test fit.  I’m fortunate to have two chucks, so that made this whole process a bit easier and more accurate.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819131.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819131" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819131_thumb.jpg" border="0" alt="ACT_819131" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819232.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819232" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819232_thumb.jpg" border="0" alt="ACT_819232" width="244" height="165" /></a></p>
<p align="left">The lid was then mounted in the lathe and the base fitted to it.  Because of the size of the box and the fact that I did not try and get a super snug fit of the lid, I taped the joint with a couple of wraps of masking tape.  I also brought the tailstock up while I finished most of the bottom of the box.  I sanded the bottom and turned some details on the bottom so that if ever another woodturner picked it up they would know that I knew how to finish the bottom of a piece <img src='http://syzygypens.com/blog/wp-includes/images/smilies/icon_smile.gif' alt=':)' class='wp-smiley' /> </p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819333.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819333" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819333_thumb.jpg" border="0" alt="ACT_819333" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819434.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819434" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819434_thumb.jpg" border="0" alt="ACT_819434" width="244" height="165" /></a></p>
<p align="left">Remember the plywood with the stave off cut from earlier that I didn’t throw away?  This was then mounted on the lathe and a recess turned in it so that the lid could be fitted to it for finishing.  I made this a nice snug fit.  With the tailstock up I finished off the majority of the top of the lid.  Then I moved the tailstock out of the way and carefully removed the tenon and sanded the top of the lid.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819535.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819535" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819535_thumb.jpg" border="0" alt="ACT_819535" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819636.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819636" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819636_thumb.jpg" border="0" alt="ACT_819636" width="244" height="165" /></a></p>
<p align="left">After much head scratching I figured out how to lay out 16 small circles symmetrically inside of one big circle.  I did this on some scrap plywood and it took a while!  I’ll try and recall how I did it and explain it:</p>
<ul>
<li>
<div>Draw a circle that is the same diameter as the lid</div>
</li>
<li>
<div>Draw a circle with the same center that is about 1/2” less in diameter.  This is going to be the circle that contains the pattern.</div>
</li>
<li>
<div>Set the compass to the same diameter that the inlay pieces are going to be and draw four circles, one on each of the lines, so that the outside of that circle touches the outside of the circle that will contain the pattern.  Circles 1 through 4.</div>
</li>
<li>
<div>Draw a square joining the center of circles 1 through 4.</div>
</li>
<li>
<div>Layout circles 5 through 12 so that the are equidistant.  i.e the gaps between circles 1 &amp;5, 5 &amp; 6 and 6 &amp; 2 are all equal.</div>
</li>
<li>
<div>Draw horizontal and vertical lines connecting the centers of those circles.</div>
</li>
<li>
<div>Where those lines intersect will determine the center of circles 13 through 16.  i.e the intersection of the line between 12 and 7 and the line between 5 and 10 will be the center of circle 13.</div>
</li>
</ul>
<p align="left">Sounds pretty simple now, but it took a couple of scrap pieces of plywood to figure that out!!</p>
<p align="left">Then transfer the pattern to the lid of the box.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819737.jpg" rel="lightbox[935]"><img style="border-bottom: 0px; border-left: 0px; display: inline; border-top: 0px; border-right: 0px" title="ACT_819737" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819737_thumb.jpg" border="0" alt="ACT_819737" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820040.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820040" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820040_thumb.jpg" border="0" alt="ACT_820040" width="244" height="165" /></a></p>
<p align="left">Then I took the lid to the drill press and drilled holes about an 1/8” deep using a forstner bit.  I used the stop on my drill press so that the holes were all the same depth.  As the lid was still attached to the plywood with a tenon on the other side I cut up some scrap two by fours and used them to hold the lid steady and level.  I took my time, doing this, knowing it would really ruin my day if I drilled a recess in the wrong spot.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820141.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820141" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820141_thumb.jpg" border="0" alt="ACT_820141" width="244" height="165" /></a></p>
<p align="left">I then mounted a piece of oak in a chuck, flattened the end and using calipers turned it to the same diameter that of the forstner bit I had used to drill the recess in the lid.  I mounted it in the same orientation as I would a bowl blank so that when the inlays were parted off the face grain would be showing in the lid.  After each piece was parted off, I did a dry test fit and then glued the inlay into the lid.  I took care not to use a lot of glue as there was no place for any excess glue to go.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819838.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_819838" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_819838_thumb.jpg" border="0" alt="ACT_819838" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820444.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820444" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820444_thumb.jpg" border="0" alt="ACT_820444" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820242.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820242" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820242_thumb.jpg" border="0" alt="ACT_820242" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820343.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820343" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820343_thumb.jpg" border="0" alt="ACT_820343" width="244" height="165" /></a></p>
<p align="left">Once all the glue had dried, the lid was mounted back on the lathe and the protruding inlays were turned down.  The lid was turned flat and sanded.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820646.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820646" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820646_thumb.jpg" border="0" alt="ACT_820646" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820747.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820747" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820747_thumb.jpg" border="0" alt="ACT_820747" width="244" height="165" /></a></p>
<p align="left">With the box complete, it was time to make all the pieces.  I needed a total of 16 pieces.  Each piece needed to have one of each of four attributes.  It needed to be tall or short, light or dark, square or round, solid or hollow.  For example the piece shown in the drill press is tall, light (oak), square and hollow (the 1/4” deep hole).  The piece shown on the lathe a couple of pictures later is tall, light (oak), round and hollow.</p>
<p align="left">So I needed 4 short oak pieces, 4 short walnut pieces, 4 tall oak pieces and 4 tall walnut pieces.</p>
<p align="left">Four of the short pieces (two oak and two walnut) would be square and four of the tall pieces (two oak and two walnut) would be round.</p>
<p align="left">Four of the short pieces (one round oak, one square oak, one round walnut and one square walnut) would be hollow and four of the tall pieces (one round oak, one square oak, one round walnut and one square walnut) would be solid.</p>
<p align="left">Simple, hey?</p>
<p align="left">First they were milled and cut to size.  Half of the pieces would be completed on the table saw and the other half would be completed on the lathe.  Those that were to be square and finished on the table saw were cut to final size.  The half that were to be round and would be completed on the lathe were cut about 3/4” to long to allow room to grip them in a chuck.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820848.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_820848" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_820848_thumb.jpg" border="0" alt="ACT_820848" width="244" height="165" /></a></p>
<p align="left">Using a crosscut sled, a stop block and a pencil with an eraser to hold the pieces while cutting, a decorative groove was cut in each of the square pieces.  No prizes for guessing that I watched David Marks in Woodworks!</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821050.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_821050" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821050_thumb.jpg" border="0" alt="ACT_821050" width="244" height="165" /></a></p>
<p align="left">The edges of each piece were then rounded over at the router table using a scrap piece of MDF as a backer block.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821151.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_821151" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821151_thumb.jpg" border="0" alt="ACT_821151" width="244" height="165" /></a></p>
<p align="left">Finally two of the tall pieces and two of the short pieces were held in my pen drilling vice and a 1/4” hole drilled in the top of each piece.  I finally found a use for the pen drilling vice!!</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821252.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_821252" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821252_thumb.jpg" border="0" alt="ACT_821252" width="244" height="165" /></a></p>
<p align="left">A similar procedure was done to the remaining pieces on the lathe.  The decorative groove was made with a parting tool and the 1/4” deep hole was drilled on the lathe.</p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821353.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_821353" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821353_thumb.jpg" border="0" alt="ACT_821353" width="244" height="165" /></a></p>
<p align="center"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821454.jpg" rel="lightbox[935]"><img style="border-right-width: 0px; display: inline; border-top-width: 0px; border-bottom-width: 0px; border-left-width: 0px" title="ACT_821454" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_821454_thumb.jpg" border="0" alt="ACT_821454" width="244" height="165" /></a></p>
<p align="left">The final step was to apply the finish to the box and pieces.</p>
<p align="left"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_8285562.jpg" rel="lightbox[935]"><img style="border-bottom: 0px; border-left: 0px; display: block; float: none; margin-left: auto; border-top: 0px; margin-right: auto; border-right: 0px" title="ACT_828556" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_828556_thumb2.jpg" border="0" alt="ACT_828556" width="244" height="165" /></a></p>
<p align="left"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_8284552.jpg" rel="lightbox[935]"><img style="border-bottom: 0px; border-left: 0px; display: block; float: none; margin-left: auto; border-top: 0px; margin-right: auto; border-right: 0px" title="ACT_828455" src="http://syzygypens.com/blog/wp-content/uploads/2009/07/ACT_828455_thumb2.jpg" border="0" alt="ACT_828455" width="244" height="165" /></a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
<li><a href='http://syzygypens.com/blog/2009/07/16/quartro-board-game/' rel='bookmark' title='Permanent Link: Quarto Board Game'>Quarto Board Game</a></li>
</ol></p>]]></content:encoded>
			<wfw:commentRss>http://syzygypens.com/blog/2009/07/26/making-a-board-game-on-the-lathe/feed/</wfw:commentRss>
		<slash:comments>2</slash:comments>
		</item>
		<item>
		<title>Closed end desk pen</title>
		<link>http://syzygypens.com/blog/2009/06/04/closed-end-desk-pen/</link>
		<comments>http://syzygypens.com/blog/2009/06/04/closed-end-desk-pen/#comments</comments>
		<pubDate>Fri, 05 Jun 2009 00:11:51 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Pen Turning]]></category>
		<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=636</guid>
		<description><![CDATA[<p>Inspiration for this pen came from some of the work of Ed Davidson. You can see more of his work at http://yoyospin.com.</p> <p>One of the fun things about turning a closed end pen is that it frees up more design considerations as you are not restricted by the hardware on the end of the [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/06/01/drilling-a-pen-blank-on-the-lathe/' rel='bookmark' title='Permanent Link: Drilling a pen blank on the lathe'>Drilling a pen blank on the lathe</a></li>
<li><a href='http://syzygypens.com/blog/2009/01/25/earring-stand/' rel='bookmark' title='Permanent Link: How to make an Earring Stand'>How to make an Earring Stand</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p>Inspiration for this pen came from some of the work of Ed Davidson.  You can see more of his work at <a href="http://yoyospin.com/" target="blank">http://yoyospin.com</a>.</p>
<p>One of the fun things about turning a closed end pen is that it frees up more design considerations as you are not restricted by the hardware on the end of the pen.</p>
<p>This pen is made using the <a href="http://www.woodcraft.com/AffiliateWiz/aw.aspx?A=223&amp;Task=Click&amp;targetURL=http://www.woodcraft.com/family.aspx?familyid=5300">Navigator </a>kit from <a href="http://www.woodcraft.com/AffiliateWiz/aw.aspx?A=223&amp;Task=Click">Woodcraft</a>.  It is the same kit that is sold as the <a href="http://www.arizonasilhouetteinc.com/cart/index.php?main_page=advanced_search_result&amp;search_in_description=1&amp;zenid=a632a18efafdee5bc7dd4fe42320ab98&amp;keyword=baron">Baron/Sedona </a>by <a href="http://www.arizonasilhouetteinc.com">Arizona Silhouette.</a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807201.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807201.jpg" alt="Closed End Desk Pen" width="200" height="300" /></a></p>
<p style="text-align: left;"><em>You can click on any of the images to see a larger version.</em></p>
<p>I started with a piece of spalted pecan, approx. 1 1/2&#8243; x 1 1/2&#8243; x 7&#8243;.   After mounting it between centers, I turned it round and then turned a tenon on one end that would fit in the step jaws of my chuck.  I then measured 2 1/4&#8243; from the end with the tenon, and parted the blank.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_805702.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_805702.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Next I mounted the blank with the tenon in the step jaws of my chuck, and drilled a 15/32&#8243; hole 1 13/16&#8243; deep.  I checked to see that the tube for the upper barrel would fit completely in the hole.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_805803.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_805803.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Then I mounted the other piece in the step jaws and drilled two holes.  The first hole was drilled to a depth of 2 7/8&#8243; with a 11/32&#8243; bit.  Then I drilled a slightly larger hole, 25/64&#8243;, to a depth of 2 1/16&#8243;.  I checked to see that the tube for the lower barrel fitted in the larger hole and sat flush with the face of the blank.<br />
The reason for the step hole is two fold.  Firstly the extra room created at the end of the hole by the smaller bit, allows space for the spring behind the rollerball cartridge.  Secondly, a shoulder is created for the tube to rest on so that it does not go to deep into the blank while being glued in.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_805904.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_805904.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Having drilled all the holes in the upper and lower barrels, rough up the brass tubes and glue them in.</p>
<p>In order to turn the pen you need an expansion mandrel of some type.  It is relatively easy to make one.  Well, lets just say some people might find it relatively easy to make one!  I tried a couple of times with not much success.  If you would like to try you can find instructions in this <a href="http://content.penturners.org/articles/2008/pinchuck.pdf">tutorial</a>.</p>
<p>I ended up buying a <a href="http://www.arizonasilhouetteinc.com/cart/index.php?main_page=product_info&amp;products_id=1669">closed end mandrel</a> for the lower barrel from Arizona Silhouette.  It looks similar to a concrete expansion bolt and operates under the same principle.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806005.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806005.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Insert the mandrel in the upper barrel, tighten the bolt using a couple of wrenches and insert the mandrel in the step jaws.  Take care not to over tighten the bolt, it is easy to crack the blank, especially if you are working with an acrylic blank.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806106.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806106.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806207.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806207.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Turn the blank down to approx. 5/8&#8243; and then measure 3 1/4&#8243; from the end and part the blank off at this point.  Then turn the blank to the shape you want, sand and apply the finish.  You will find that you need to support the blank with your fingers on the back side while turning to help reduce vibration.  It also helps to take light cuts.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806611.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806611.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>The next step is to turn the upper barrel.  Because the brass tube is a different size the mandrel will not work.  You have two choices at this point.  The first is to buy another <a href="http://www.arizonasilhouetteinc.com/cart/index.php?main_page=product_info&amp;products_id=1794">mandrel </a>sized for the upper barrel.  This could get expensive, especially if you want to also make closed end pens from other kits as well.</p>
<p>Fortunately, for the frugal amongst us, there is another solution.  I got this <a href="http://www.penturners.org/forum/showthread.php?t=40199&amp;highlight=closed+end">idea </a>from Ben &#8220;DaVinci27&#8243; Brown.</p>
<p>Take a spare <strong>lower </strong>barrel tube and glue it in a blank.  I would recommend using 5 minute epoxy as you want to make sure you fill all the voids between the tube and the inside of the blank.  Mount the blank on the lathe between a 60 degree live center and a 60 degree dead center.  Turn the blank down to a diameter that makes it a snug fit inside the tube from an <strong>upper </strong>barrel.  Go slow and use calipers to check your progress.  Then take that blank to your band saw and cut it in half along the length.  Don&#8217;t cut along the whole length of the blank, just about half way.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806914.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_806914.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Insert that tube in the tube of your upper barrel, then insert the mandrel and tighten.  The cut in the tube will allow it to expand as you tighten the mandrel and hold the blank snug on the mandrel.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807015.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807015.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Turn the upper blank to the shape you want, sand and finish.  Once again you will probably find it necessary to support the back of the blank with your fingers while turning.  Light cuts also help.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807116.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807116.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>
<p>Here are a couple more shots of the finished pen.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807302.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807302.jpg" alt="Closed End Desk Pen" width="200" height="300" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807417.jpg" rel="lightbox[636]"><img class="size-medium wp-image-69 alignnone" title="Closed End Desk Pen" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/06/ACT_807417.jpg" alt="Closed End Desk Pen" width="300" height="200" /></a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/06/01/drilling-a-pen-blank-on-the-lathe/' rel='bookmark' title='Permanent Link: Drilling a pen blank on the lathe'>Drilling a pen blank on the lathe</a></li>
<li><a href='http://syzygypens.com/blog/2009/01/25/earring-stand/' rel='bookmark' title='Permanent Link: How to make an Earring Stand'>How to make an Earring Stand</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
</ol></p>]]></content:encoded>
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		<title>Lidded Box</title>
		<link>http://syzygypens.com/blog/2009/04/23/lidded-box/</link>
		<comments>http://syzygypens.com/blog/2009/04/23/lidded-box/#comments</comments>
		<pubDate>Thu, 23 Apr 2009 11:40:27 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=527</guid>
		<description><![CDATA[<p>Making a simple lidded box is a fun project.</p> <p style="text-align: center;"></p> <p style="text-align: left;">You can click on any of the images to see a larger version.</p> <p>I started with a piece of spalted sweetgum just over 2&#8243; x 2&#8243; square. I placed it on the lathe between centers and turned it round. I [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/28/turning-a-hollow-sphere/' rel='bookmark' title='Permanent Link: Turning a hollow sphere'>Turning a hollow sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/06/20/lidded-bowl/' rel='bookmark' title='Permanent Link: Lidded Bowl'>Lidded Bowl</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p>Making a simple lidded box is a fun project.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786710.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786710.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p style="text-align: left;"><em>You can click on any of the images to see a larger version.</em></p>
<p>I started with a piece of spalted sweetgum just over 2&#8243; x 2&#8243; square.  I placed it on the lathe between centers and turned it round.  I formed a tenon on each side to fit my chuck jaws, marked the line dividing the base and the lid and then parted at that line.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_785601.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_785601.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>I then mounted the lid section in my chuck and turned it true.  I rough hollowed the inside of the lid and then cut the lid flange.  It is important that the lid flange is the same diameter throughout its length.  The sides must run parallel to ensure a nice fit to the base flange.  I then finished hollowing the inside of the lid and sanded that.  I trued the rim and rough shaped the outside of the lid.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_785702.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_785702.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>Next I mounted the base section and established the approximate diameter of the base flange.  I hollowed out the base and marked the depth on the outside of the blank.  I parted to the headstock side of that line to a depth of about 1/2&#8243;.  I then sanded the inside of the base.  The next step was to refine the flange so that the lid was a tight fit.  Go slowly on this step, it is very easy to overshoot and end up with a loose fitting lid.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_785903.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_785903.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>I mounted the lid to the base and shaped the outside profile of the lid and base, including detailing the joint with a small bead either side.  Just to be safe I brought the tail stock up during this stage.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786004.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786004.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786105.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786105.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>I then parted off the lid and refined the fit of the base flange to the lid.  I sanded the base and then parted it off.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786206.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786206.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786307.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786307.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>Using the piece of wood left in my chuck I formed a tenon to make a jam chuck that the base was reverse mounted on in order to finish the bottom of the base.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786508.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786508.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>As you can see from the next image the piece that I used for my jam chuck proved to be to small and punky.  I had to make another jam chuck from some scrap wood in order to reverse mount the base.  Here it is with the bottom finished and sanded.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786609.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786609.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>The completed box, ready for a coat of finish.  If you plan on applying a friction polish then it is best to do that on lathe after each sanding step.  I finished my box with a couple coats of spray lacquer.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786710.jpg" rel="lightbox[527]"><img class="size-medium wp-image-69 alignnone" title="Lidded Box" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/04/ACT_786710.jpg" alt="Lidded Box" width="300" height="200" /></a></p>
<p>A great book to read is &#8220;Turning Boxes&#8221; by Richard Raffan.  He covers all the details of turning a box, from cutting out the blanks to design considerations.</p>
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<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/28/turning-a-hollow-sphere/' rel='bookmark' title='Permanent Link: Turning a hollow sphere'>Turning a hollow sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/06/20/lidded-bowl/' rel='bookmark' title='Permanent Link: Lidded Bowl'>Lidded Bowl</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
</ol></p>]]></content:encoded>
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		<title>Making a Tool Handle &#8211; Part Three</title>
		<link>http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/</link>
		<comments>http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/#comments</comments>
		<pubDate>Thu, 05 Mar 2009 23:20:50 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>
		<category><![CDATA[Woodworking]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=354</guid>
		<description><![CDATA[<p>To read Part One click here To read Part Two click here</p> <p>If you are interested in buying one of these tools they can be purchased at Woodchuck Lathe Tools</p> <p>I got a chance to turn the handles today. I mounted the blank between centers, locating a 60 degree live center in the channel [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/03/making-a-tool-handle-part-two/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Two'>Making a Tool Handle &#8211; Part Two</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/12/handle-for-new-tool/' rel='bookmark' title='Permanent Link: Handle for new tool'>Handle for new tool</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p><em>To read Part One click <a href="http://syzygypens.com/blog/?p=325">here</a></em><br />
<br /><em>To read Part Two click <a href="http://syzygypens.com/blog/?p=347">here</a></em></p>
<p><strong><em>If you are interested in buying one of these tools they can be purchased at <a href="http://www.woodchuck-tools.com/" target="blank">Woodchuck Lathe Tools</a></em></strong></p>
<p>I got a chance to turn the handles today.  I mounted the blank between centers, locating a 60 degree live center in the channel opening at the headstock.  After turning it round, I turned a tenon at the headstock side, sized to accept a brass coupler.  I used a 1&#8243; brass coupler cut in half.  The coupler was originally just shy of 2&#8243; long.  I also marked the high points and low points of the handle and using a parting tool cut down to the final diameter of the handle at those points.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751401.jpg" rel="lightbox[354]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751401.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p><em>You can click on any of the images to see a larger version.</em></p>
<p>Here is a shot of the handle, sanded and ready to be parted off.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751502.jpg" rel="lightbox[354]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751502.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p>I used 5 minute epoxy to secure the tools in the handle and to secure the brass coupler on the tenon.  I finished the handles with a couple of coats of spray shellac.  While not as hard wearing as some other finishes I like the feel of shellac.  It is also not as shiny as some other finishes, which is fine by me for a tool handle.  Lastly shellac is very repairable, any future coats will melt into previous coats.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751603.jpg" rel="lightbox[354]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751603.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p>I&#8217;m looking forward to trying out the tools tomorrow and giving a review of them.</p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/03/making-a-tool-handle-part-two/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Two'>Making a Tool Handle &#8211; Part Two</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/12/handle-for-new-tool/' rel='bookmark' title='Permanent Link: Handle for new tool'>Handle for new tool</a></li>
</ol></p>]]></content:encoded>
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		<slash:comments>5</slash:comments>
		</item>
		<item>
		<title>Making a Tool Handle &#8211; Part Two</title>
		<link>http://syzygypens.com/blog/2009/03/03/making-a-tool-handle-part-two/</link>
		<comments>http://syzygypens.com/blog/2009/03/03/making-a-tool-handle-part-two/#comments</comments>
		<pubDate>Wed, 04 Mar 2009 02:36:51 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>
		<category><![CDATA[Woodworking]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=347</guid>
		<description><![CDATA[<p>To read Part One click here</p> <p>If you are interested in buying one of these tools they can be purchased at Woodchuck Lathe Tools</p> <p>My tools arrived today! I&#8217;m glad I waited before gluing the handle blanks together. Either my 1/2&#8243; router bit is not exactly 1/2&#8243; or 1/2&#8243; square bar is not 1/2&#8243;. [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Three'>Making a Tool Handle &#8211; Part Three</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/12/handle-for-new-tool/' rel='bookmark' title='Permanent Link: Handle for new tool'>Handle for new tool</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p><em>To read Part One click <a href="http://syzygypens.com/blog/?p=325">here</a></em></p>
<p><strong><em>If you are interested in buying one of these tools they can be purchased at <a href="http://www.woodchuck-tools.com/" target="blank">Woodchuck Lathe Tools</a></em></strong></p>
<p>My tools arrived today!  I&#8217;m glad I waited before gluing the handle blanks together.  Either my 1/2&#8243; router bit is not exactly 1/2&#8243; or 1/2&#8243; square bar is not 1/2&#8243;.  Either way the tool bar did not fit in the grooves I had routed.  The depth of the grooves was fine, but the width was a hair to small.  I increased the width fractionally on the router table and the fit was perfect.</p>
<p>Here is a shot of one of the blanks glued and clamped.  I left the bar in the groove temporarily while doing the glue up to make sure the channel lined up nicely.  As soon as I was done clamping, I pulled the bar out.  I also marked on the bar the depth it receded in the channels.  I know I will have some clean up to do in the channels due to glue squeeze out and I want to make sure the bar is able to fit in as deeply as it did during the dry fit.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_750802.jpg" rel="lightbox[347]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_750802.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p><em>You can click on any of the images to see a larger version.</em></p>
<p>Here are a couple of shots of the business end of the two tools.  One has the carbide cutter in place, the other just the holding screw.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751206.jpg" rel="lightbox[347]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751206.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751004.jpg" rel="lightbox[347]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/03/ACT_751004.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p><em><a href="http://syzygypens.com/blog/?p=354">Making a Tool Handle &#8211; Part Three</a></em></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part One'>Making a Tool Handle &#8211; Part One</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Three'>Making a Tool Handle &#8211; Part Three</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/12/handle-for-new-tool/' rel='bookmark' title='Permanent Link: Handle for new tool'>Handle for new tool</a></li>
</ol></p>]]></content:encoded>
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		<slash:comments>0</slash:comments>
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		<item>
		<title>Turning a hollow sphere</title>
		<link>http://syzygypens.com/blog/2009/02/28/turning-a-hollow-sphere/</link>
		<comments>http://syzygypens.com/blog/2009/02/28/turning-a-hollow-sphere/#comments</comments>
		<pubDate>Sat, 28 Feb 2009 13:12:51 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=333</guid>
		<description><![CDATA[<p>I&#8217;m still having a ball turning spheres! This is how I turned a hollow sphere. I first mounted a piece of wood about 3 1/2&#8243; square by 5 1/2&#8243; long between centers and turned it round with tenons either side sized to fit my jaw chuck. I measured the diameter of the cylinder at [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/25/turning-a-sphere/' rel='bookmark' title='Permanent Link: Turning a sphere'>Turning a sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/23/lidded-box/' rel='bookmark' title='Permanent Link: Lidded Box'>Lidded Box</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p>I&#8217;m still having a ball turning spheres!  This is how I turned a hollow sphere.  I first mounted a piece of wood about 3 1/2&#8243; square by 5 1/2&#8243; long between centers and turned it round with tenons either side sized to fit my jaw chuck.  I measured the diameter of the cylinder at the center point and it was 3 1/4&#8243;.   I then parted the cylinder in half.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749101.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749101.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p style="text-align: left;"><em>You can click on any of the images to see a larger version.</em></p>
<p style="text-align: left;"><span id="more-333"></span></p>
<p>Given the outside diameter of the cylinder at 3 1/4&#8243; I decided to make the internal diameter of the sphere 3&#8243;.  In order to create a template to use while hollowing the sphere I cut a 3 1/4&#8243; x 3 1/4&#8243; piece of hardboard and attached it with double sided tape to a piece of scrap held in a chuck.  Using a parting tool I made a 3&#8243; circle from the hardboard.  I alse drew lines through the center of the hardboard.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749202.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749202.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p>I mounted one half of the cylinder in my jaw chuck and using a spindle gouge and a round nose scraper I hollowed it out, checking frequently with the template to make sure I was hollowing half a sphere.  I also turned a tenon on the end.  Then I sanded the inside.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749303.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749303.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p>I repeated this with the other half of the cylinder, except I turned a mortise on the end.  I established the diameter of the mortise first, sneaking up and performing many test fits with the other half of the cylinder.  Once the diameter was established, I established the depth until the two halves fit together nicely.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749404.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749404.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749505.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749505.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p>After bringing up the tail stock, I then proceeded turn the outside of the sphere.  For details on turning a sphere please click <a href="http://syzygypens.com/blog/?p=317" target="blank">here</a>.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749606.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749606.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p>Before I removed the sphere from between centers and mounted it in the cup centers I taped the two halves together.  </p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749707.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749707.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p>The finished sphere, not as perfectly round as some I&#8217;ve done before, but this one is hollow!</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749808.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749808.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749909.jpg" rel="lightbox[333]"><img class="size-medium wp-image-69 alignnone" title="Turning a Hollow Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_749909.jpg" alt="Turning a Hollow Sphere" width="300" height="200" /></a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/25/turning-a-sphere/' rel='bookmark' title='Permanent Link: Turning a sphere'>Turning a sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/22/donut-chuck/' rel='bookmark' title='Permanent Link: Make a Donut Chuck'>Make a Donut Chuck</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/23/lidded-box/' rel='bookmark' title='Permanent Link: Lidded Box'>Lidded Box</a></li>
</ol></p>]]></content:encoded>
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		<slash:comments>2</slash:comments>
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		<item>
		<title>Making a Tool Handle &#8211; Part One</title>
		<link>http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/</link>
		<comments>http://syzygypens.com/blog/2009/02/26/making-a-tool-handle-part-one/#comments</comments>
		<pubDate>Thu, 26 Feb 2009 12:36:56 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>
		<category><![CDATA[Woodworking]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=325</guid>
		<description><![CDATA[<p>If you are interested in buying one of these tools they can be purchased at Woodchuck Lathe Tools</p> <p>I am waiting on arrival of two tools a friend is making up for me. They are for lathe work and accept radius carbide cutter inserts. The tools are made from some 1/2&#8243; x 1/2&#8243; x [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/03/03/making-a-tool-handle-part-two/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Two'>Making a Tool Handle &#8211; Part Two</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Three'>Making a Tool Handle &#8211; Part Three</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/12/handle-for-new-tool/' rel='bookmark' title='Permanent Link: Handle for new tool'>Handle for new tool</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p><strong><em>If you are interested in buying one of these tools they can be purchased at <a href="http://www.woodchuck-tools.com/" target="blank">Woodchuck Lathe Tools</a></em></strong></p>
<p>I am waiting on arrival of two tools a friend is making up for me.  They are for lathe work and accept radius carbide cutter inserts.  The tools are made from some 1/2&#8243; x 1/2&#8243; x 18&#8243; square steel bar that I sent him.  He is milling a slot in one end of the bar for the cutter to seat, as well as tapping a hole to secure the cutter.  I told him not to worry about turning the other end of the tool round to insert in the handle.</p>
<p>I&#8217;m excited to try out the tool and so have started preparing the stock I will be using for the tool handles.  My first step was to take four pieces of 4 pieces of cherry and 4 pieces of maple, each piece was 3/4&#8243; x 3&#8243; x 15&#8243;.  I milled and cut each piece down to 5/8&#8243; x 2 1/2&#8243; x 15&#8243; and glued them together.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_742201.jpg" rel="lightbox[325]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_742201.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p><em>You can click on any of the images to see a larger version.</em></p>
<p>I then mounted a 1/2&#8243; straight bit in my router table and raised it 1/4&#8243; above the router table.  I set the fence 1&#8243; from the edge of the bit and also set up a stop block 4&#8243; from the near side of the bit.  Using this set up I routed a 1/4&#8243; x 1/2&#8243; x 4&#8243; stopped groove in each of the four pieces.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_742302.jpg" rel="lightbox[325]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_742302.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p>Finally, I squared the end of each groove using hand chisels.  I was tempted to glue the pieces together but decided to wait until the tools arrived so I could do a test fit of the bars in the grooves.  </p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_742403.jpg" rel="lightbox[325]"><img class="size-medium wp-image-69 alignnone" title="Making a Tool Handle" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_742403.jpg" alt="Making a Tool Handle" width="300" height="200" /></a></p>
<p><a href="http://syzygypens.com/blog/?p=347">Making a Tool Handle &#8211; Part Two</a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/03/03/making-a-tool-handle-part-two/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Two'>Making a Tool Handle &#8211; Part Two</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/05/making-a-tool-handle-part-three/' rel='bookmark' title='Permanent Link: Making a Tool Handle &#8211; Part Three'>Making a Tool Handle &#8211; Part Three</a></li>
<li><a href='http://syzygypens.com/blog/2009/04/12/handle-for-new-tool/' rel='bookmark' title='Permanent Link: Handle for new tool'>Handle for new tool</a></li>
</ol></p>]]></content:encoded>
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		<slash:comments>0</slash:comments>
		</item>
		<item>
		<title>Turning a sphere</title>
		<link>http://syzygypens.com/blog/2009/02/25/turning-a-sphere/</link>
		<comments>http://syzygypens.com/blog/2009/02/25/turning-a-sphere/#comments</comments>
		<pubDate>Wed, 25 Feb 2009 12:52:33 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=317</guid>
		<description><![CDATA[<p>At the demo by Fred Holder I attended he turned a sphere and used a set of sphere calipers. They are available online, but are pricey, so I did some more searching and found a great article by Al Hockenbery. It involves a bit of math but is a fairly quick and easy way [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/28/turning-a-hollow-sphere/' rel='bookmark' title='Permanent Link: Turning a hollow sphere'>Turning a hollow sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/08/narra-sphere/' rel='bookmark' title='Permanent Link: Narra Sphere'>Narra Sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/20/spheres/' rel='bookmark' title='Permanent Link: Spheres'>Spheres</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p>At the demo by Fred Holder I attended he turned a sphere and used a set of sphere calipers.  They are available online, but are pricey, so I did some more searching and found a great article by Al Hockenbery.  It involves a bit of math but is a fairly quick and easy way to turn a sphere on the lathe.  This article describes and illustrates the process.</p>
<p>I&#8217;m having a lot of fun turning these spheres and have also decided to start a wood collection and am going to turn my collection into spheres!  One of the nice things about the spheres is that they show off the end, face and side grain in a small area. They also look so cool and feel so good to hold!</p>
<p>If anyone else is doing this already or is interested in starting I’d love to hear from you. If you’re interested in trading wood to make spheres or trading the spheres themselves let me know. I find a nice size piece of wood to start with is 3&#8243; x 3&#8243; x 4 1/2&#8243;. </p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_748115.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_748115.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p style="text-align: left;"><em>You can click on any of the images to see a larger version.</em></p>
<p style="text-align: left;"><span id="more-317"></span></p>
<p>First the math.  You first need to turn a cylinder that is round in cross section.  Then you will turn that into a octagon and finally turn that into a 16 sided polygon before blending all the angles into a perfect circle.  The pictures below illustrate this and you can see that the sides of the octagon are 0.414 x the diameter of the initial square.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/balls.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/balls.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/balls1.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/balls1.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Mount a piece of wood between centers.  A 3&#8243; x 3&#8243; x 4 1/2&#8243; piece is a nice size, yielding a sphere about 2 3/4&#8243; diameter which fits in your hand nicely and feels good to hold.  Grain orientation is not important, although it will affect your choice of turning tool.  I like to use a bowl gouge to rough turn the cylinder.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746401.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746401.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Mark the center point of the cylinder and find the diameter at that point. Layout that dimension on the cylinder, centering it about your first mark.  </p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746602.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746602.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Now turn tenons on either side of the cylinder.  Turn the tenons down to a diameter of 0.414D.  (D = diameter of the cylinder)</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746803.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746803.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Now layout two more lines on the cylinder that are 0.414D apart and are centered around the center line of the cylinder.  Make a straight cut from these lines to the edge of the tenons.  You should now have a shape that is an octagon in cross section.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746904.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_746904.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Mark the center point of each of the newly created flat areas.  These two marks, along with the first mark on the center line of the cylinder, will be on the surface of the sphere.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747005.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747005.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Turn the tenons down a bit more.  Then mark the center points of each area between the lines and the edge of the flat area.  These are the red lines in the image below. </p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747206.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747206.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Make straight cuts between adjacent red lines to turn the octagon into a 16 sided polygon.  Try make the cuts as straight as you can, you can see in the picture below that one of mine ended up a bit concave.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747307.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747307.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Using a bowl gouge or a skew held flat like a scraper, blend all the flat parts in, creating the sphere.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747408.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747408.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>In order to finish the sphere and turn off the tenons it needs to be mounted between a set of cup centers.  To make the cup center for the headstock side chuck a piece of scrap in a jaw chuck and hollow it out slightly.  Make sure that the sphere fits against the edge of the concave are and does not bottom out in the hollow.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747509.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747509.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Next mount another piece of scrap in the jaw chuck and hollow out a v shaped hollow.  Place a 60 degree live center in the tailstock and check that it fits snugly in the v shaped hollow.  Turn a tenon on the end of the piece.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747610.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747610.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747711.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747711.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Turn the scrap piece around and remount it in the jaw chuck using the newly created tenon.  Hollow a cup on this end. </p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747812.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747812.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>Mount the sphere between the two cup centers and carefully turn the tenons off.  As you can see I cut the majority of the tenon off with a handsaw.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747913.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_747913.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_748014.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_748014.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>
<p>When sanding the sphere I put a piece of high friction router mat between the cups and the sphere to protect the wood.  I also re-orientate the sphere between the cup centers a number of times in order to get the sphere as round as possible and to sand the whole surface.</p>
<p style="text-align: center;"><a href="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_748115.jpg" rel="lightbox[317]"><img class="size-medium wp-image-69 alignnone" title="Turning a Sphere" src="http://www.syzygypens.com/blog/wp-content/uploads/2009/02/ACT_748115.jpg" alt="Turning a Sphere" width="300" height="200" /></a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/02/28/turning-a-hollow-sphere/' rel='bookmark' title='Permanent Link: Turning a hollow sphere'>Turning a hollow sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/03/08/narra-sphere/' rel='bookmark' title='Permanent Link: Narra Sphere'>Narra Sphere</a></li>
<li><a href='http://syzygypens.com/blog/2009/02/20/spheres/' rel='bookmark' title='Permanent Link: Spheres'>Spheres</a></li>
</ol></p>]]></content:encoded>
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		<title>Make a Donut Chuck</title>
		<link>http://syzygypens.com/blog/2009/02/22/donut-chuck/</link>
		<comments>http://syzygypens.com/blog/2009/02/22/donut-chuck/#comments</comments>
		<pubDate>Sun, 22 Feb 2009 12:05:28 +0000</pubDate>
		<dc:creator>Keith Larrett</dc:creator>
				<category><![CDATA[Projects]]></category>
		<category><![CDATA[Tools, jigs and accessories]]></category>
		<category><![CDATA[Woodturning]]></category>

		<guid isPermaLink="false">http://syzygypens.com/blog/?p=305</guid>
		<description><![CDATA[<p>I needed to make a donut chuck so that I could mount a 12&#8243; bowl on my lathe and finish off the bottom of the bowl. I have a set of cole jaws for my jaw chuck, but they will only expand 10&#8243;. </p> <p style="text-align: center;"></p> <p style="text-align: left;">You can click on any [...]


Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/12/21/chuck-reversing-adapter/' rel='bookmark' title='Permanent Link: Chuck Reversing Adapter'>Chuck Reversing Adapter</a></li>
<li><a href='http://syzygypens.com/blog/2010/01/25/threaded-wooden-dowels/' rel='bookmark' title='Permanent Link: Threaded wooden dowels'>Threaded wooden dowels</a></li>
<li><a href='http://syzygypens.com/blog/2009/07/26/making-a-board-game-on-the-lathe/' rel='bookmark' title='Permanent Link: Making a Board Game on the lathe'>Making a Board Game on the lathe</a></li>
</ol>]]></description>
			<content:encoded><![CDATA[<p>I needed to make a donut chuck so that I could mount a 12&#8243; bowl on my lathe and finish off the bottom of the bowl.  I have a set of cole jaws for my jaw chuck, but they will only expand 10&#8243;.   </p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744806.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744806.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>
<p style="text-align: left;"><em>You can click on any of the images to see a larger version.</em></p>
<p style="text-align: left;"><span id="more-305"></span></p>
<p>The first step was to take a 16&#8243; x 16&#8243; x 3/4&#8243; piece of plywood and find the center.  I marked out three circles of 9&#8243;, 15&#8243; and 15 3/4&#8243; diameter.  I laid out eight points on the 15&#8243; diameter circle and drilled 5/16&#8243; holes and inserted 1/4-20 tee nuts at each of these points.</p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744101.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744101.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>
<p>I took another piece of 16&#8243; x 16&#8243; x 3/4&#8243; plywood and placed it below the first piece.  Using a transfer punch, I transferred the centers of the eight tee nuts to the second piece of plywood and then drilled 1/4&#8243; holes at each of these points.  I bolted the two pieces together using 1 1/2&#8243; 1/4-20 bolts and cut the two pieces of plywood round, just outside of the 15 3/4&#8243; circle.  I used my jigsaw to do this as the workpiece would not have sat flush on my band saw table and I did not want the heads of the bolts to scratch my band saw table.  As an aside, I used the new Xtra-Clean (T308B) blades from Bosch and was impressed at how easily they cut and how clean the cut was on both the top and bottom of the plywood.</p>
<p>Using my <a href="http://syzygypens.com/blog/?p=302">center finder</a> I located a face plate I have dedicated to this donut chuck and attached it securely to the first piece of plywood. </p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744302.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744302.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>
<p>I mounted the face plate and plywood pieces on the lathe and turned both pieces perfectly round.  I marked a 9&#8243; diameter circle on the front piece and drilled a 1/.4&#8243; hole through both pieces using a drill chuck in the tail stock.  I took the piece of the lathe and drilled a 5/16&#8243; hole 3/8&#8243; deep in the back piece of plywood and inserted a 1/4&#8243; tee nut in that hole.  Then I bolted both pieces together suing another 1 1/2&#8243; 1/4-20 bolt.</p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744403.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744403.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744504.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744504.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>
<p>I remounted the piece on the lathe and made a mark on the sides of the plywood pieces to help align the two pieces. Using a parting tool, I cut the 9&#8243; diameter circle out of the front piece of plywood.  I cut at an angle from the center out and took care to make sure I did not cut too deeply into the back piece of plywood.  Because of the tapered cut and the center bolt the internal circle did not come loose.  I had to remove all 9 bolts to take it out.</p>
<p>Lastly I cut a piece of high friction router pad cloth and using spray adhesive attached it to the inside face of the front section.  This will help to both hold and protect the surface of the bowl.</p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744705.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744705.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>
<p>The tee nut inserted in the center of the back piece can be used to mount a scrap piece of plywood to.  A tenon that matches the internal diameter of a bowl can then be turned onto that scrap piece enabling you to mount the bowl in the donut chuck directly on center.</p>
<p>In my excitement at how easily the bowl mounted and how smooth and true it ran, I forgot to take a picture of the mounted bowl before I finished off the bottom.  Here is a shot of the bowl mounted in the donut chuck, with the bottom finished and sanded.</p>
<p style="text-align: center;"><a href="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744806.jpg" rel="lightbox[305]"><img class="size-medium wp-image-69 alignnone" title="Donut Chuck" src="http://syzygypens.com/blog/wp-content/uploads/2009/02/ACT_744806.jpg" alt="Donut Chuck" width="300" height="200" /></a></p>


<p>Related posts:<ol><li><a href='http://syzygypens.com/blog/2009/12/21/chuck-reversing-adapter/' rel='bookmark' title='Permanent Link: Chuck Reversing Adapter'>Chuck Reversing Adapter</a></li>
<li><a href='http://syzygypens.com/blog/2010/01/25/threaded-wooden-dowels/' rel='bookmark' title='Permanent Link: Threaded wooden dowels'>Threaded wooden dowels</a></li>
<li><a href='http://syzygypens.com/blog/2009/07/26/making-a-board-game-on-the-lathe/' rel='bookmark' title='Permanent Link: Making a Board Game on the lathe'>Making a Board Game on the lathe</a></li>
</ol></p>]]></content:encoded>
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