tag:blogger.com,1999:blog-19024086415867927822024-03-05T04:04:50.535-05:00Hardware Aesthetic Shop NotesThoughts on techniques, tools, materials, and the design process.Unknownnoreply@blogger.comBlogger49125tag:blogger.com,1999:blog-1902408641586792782.post-38818510428254834152018-11-14T15:14:00.000-05:002018-11-14T15:14:51.327-05:00Making bamboo ringsI've had a steady stream of custom orders for bamboo rings. The first step is to establish the ring size with a closely-match twist drill. I find that if I get the drill press speed and feed rate correct, I can get a very clean bore that requires only light sanding.<br />
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There is not a very good agreement between standard drill sizes and standard ring sizes, but in this case, close seems to work just fine. This is the reference chart that I use:<br />
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<a href="http://en.wikipedia.org/wiki/Ring_size">Ring size on wikipedia</a><br />
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So for example, to turn a size 8 ring I need a drill that is 0.714 inches. The closest drill is 23/32", which is more like size 8 1/8. An 8 1/8 ring is indistinguishable from a size 8 ring for most practical purposes, but the imprecision bothers me. ;-)<br />
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To make a chuck of sorts for these rings, I rip a 2x4 in half and throw a length on the lathe between centres. As I turn a slight cone at the right side for the rings, I end up using more and more of the scrap wood until I have to start over. But the goal is to slightly undersize the chuck so that the ring is a firm fit when a small piece of fine sandpaper is wrapped around the wood. Without sandpaper, the ring just spins and burns.<br />
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I've found the bamboo plywood scraps that I use challenging to turn in the past. The bamboo and adhesive tend to dull tools, and using a gouge risks a catch that tears the work in half along a glueline. So I stick with a square scraper to round and then gently roll the outside form of the ring.<br />
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All of my small pieces are shipped in a handmade, recycled card box. This one is made from an empty tissue carton.<br />
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The rings are worth the trouble. I love the bands of bamboo fibre bundles sliced at different angles.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-29846597266069381832011-05-10T07:46:00.000-04:002011-05-10T07:46:51.682-04:00Building a cut-down bike scooter, part 4The scooter frame was complete and had been brushed free of grime, finish, and weld slag. All it needed was a deck to stand on. I started by experimenting with a skateboard-style wooden deck, but it seemed visually wrong and probably too prone to wear and breakage.<br />
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I liked and so didn't remove the Iron Horse crest from the steering tube.<br />
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I decided that what I really wanted was freewheel sprockets on the deck. I played with positioning some and liked how they looked, and liked that they articulated the theme of a cut-down bicycle.<br />
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My client was justifiably concerned about the sharp and jagged teeth of the sprockets chewing up the rider's ankles, though, and I had to find a way around that. But I decided to commit to the gears and welded them in place.<br />
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After some thought, I decided to cut sections out of a wheel rim and weld them in place on either side of the deck to define its edges and protect the rider from the sprockets. If I had arrived at that plan before welding on the sprockets, I would have placed the largest gear in the centre, at the widest part of the deck. But sometimes I have to make a stand and resolve the remaining problems later to move forward.<br />
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With everything welded down, the scooter was complete. The deck was wide, comfortable, and stable.<br />
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This is the completed commission. I was very happy with it and rode it around the neighbourhood for a while before giving it up to my client.<br />
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Nice ride!Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-17946222797552023862011-04-01T11:54:00.000-04:002011-04-01T11:54:54.338-04:00Building a cut-down bike scooter, part 3With the down tube wrapped around the front wheel and the top tube inverted and moved to the deck, the next step was to find a way to attach a rear wheel. I removed the front wheel from an abandoned child's bike, installed it in the rear dropouts, and positioned it to see how it would look.<br />
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I was pleased with the possibilities, and committed to it by cutting off the bottom bracket and what was left of the seat tube.<br />
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Positioned this way, it started to have a dragster sort of feel to it, which I liked. To get the chain stays level with the deck, I decided to bend them just at the edge of the wheel.<br />
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Again, I cut wedges out of the tubes so that they would bend easily and precisely. I had previously removed material from the dropouts so that I would be able to bend the seat stays down toward the deck, and you can see the missing sections here.<br />
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I placed the stays back into position for a final check before bending the stay assemblies closed.<br />
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I heated the dropouts where I wanted them to bend, to just shy of their melting point, and then gently closed the triangles.<br />
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With those assemblies completed, the whole frame was ready to weld together. The seat stays are inserted inside the top tube, and the chain stays spread outside it.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjkVV6fTjBA9gab2MM-j8RnudyUGSZgantw6ctvGlE1rhsYil9okvWejtBDOTiQzvEvVUQ33t5EvGmIHvVFab_7lwdxE5fMn7G_ablZjqiko5DI1QgZ_O7N3FVnUtPluuNKtbZuMmNyNU/s1600/P8270066.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjkVV6fTjBA9gab2MM-j8RnudyUGSZgantw6ctvGlE1rhsYil9okvWejtBDOTiQzvEvVUQ33t5EvGmIHvVFab_7lwdxE5fMn7G_ablZjqiko5DI1QgZ_O7N3FVnUtPluuNKtbZuMmNyNU/s320/P8270066.jpg" width="320" /></a></div><br />
Here's the completed frame, with the tack welds completed and the rear triangles welded closed.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYaFqszFWE_0DIwz-N_pOxRsIH1htcioyNDl0zXOBp4zePwHUUZHsRkOahSki5yHeHTj8OpY70qhHXJM-kAo49wApWsM0JmG__VpGxrxmZAcqeyySJJ_n0zWrYPwp_rKmZMiOXhIBZ_h4/s1600/P8270076.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYaFqszFWE_0DIwz-N_pOxRsIH1htcioyNDl0zXOBp4zePwHUUZHsRkOahSki5yHeHTj8OpY70qhHXJM-kAo49wApWsM0JmG__VpGxrxmZAcqeyySJJ_n0zWrYPwp_rKmZMiOXhIBZ_h4/s320/P8270076.jpg" width="320" /></a></div><br />
It was ridable in this state, and my hopes were realized -- it was way too much fun to ride. I did have to lock out the travel in the front shocks, though. Every time I gave a good kick the deck hit the ground. I drilled through the shocks and brazed in a section of bolt to keep them from compressing. The final steps were to brush the frame free of finish, complete the deck, and apply a few coats of wax to slow the rusting. At this stage, I still hadn't figured out how to make a deck to stand on.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-40382593335867078132011-03-09T10:35:00.000-05:002011-03-09T10:35:43.744-05:00Building a cut-down bike scooter, part 2I decided that the deck of the scooter would be built on the top tube of the bicycle. Flipped upside down, the seat tube could extend upward to meet the down tube, which had been wrapped around the front wheel but didn't come close enough to the ground to meet the deck.<br />
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So, I separated the seat stays from the top tube.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheD4IbYJDqydCshEaMCPz7R0NlRSBHwUvWa4dF8TRhd-D29aUFH_pyvxsYzO0lYAKM9Zy1s8oTBWjkfksLLYlOv-0ZqdGxb3PW685xDv69qX-jBdrIhSczM4OLQQxPYuuyWo8Bszx7DwY/s1600/P8270033.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheD4IbYJDqydCshEaMCPz7R0NlRSBHwUvWa4dF8TRhd-D29aUFH_pyvxsYzO0lYAKM9Zy1s8oTBWjkfksLLYlOv-0ZqdGxb3PW685xDv69qX-jBdrIhSczM4OLQQxPYuuyWo8Bszx7DwY/s320/P8270033.jpg" width="320" /></a></div><br />
The seat post sleeve and gusset would drag on the ground, so I removed them also.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcj8pxT3d5k3AKepX0fv42dgBo4JC-pRiBWNDc0_m0qYxk_YiLLF_4Xh10PIFriv30XjKnRzfFyCFiFRcTkWwGxnK2XIxgMhwxe3mF7dKCmpFCgc-6M4ygeVFiN1LuTxBVA5a1T8Xuw1k/s1600/P8270035.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcj8pxT3d5k3AKepX0fv42dgBo4JC-pRiBWNDc0_m0qYxk_YiLLF_4Xh10PIFriv30XjKnRzfFyCFiFRcTkWwGxnK2XIxgMhwxe3mF7dKCmpFCgc-6M4ygeVFiN1LuTxBVA5a1T8Xuw1k/s320/P8270035.jpg" width="320" /></a></div><br />
Then, with some trial-and-error fitting, I decided where to cut the seat tube and separated it from the stays. The photo below shows the two sections of the bike that remained.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSWbAxGwWBnkZIhuFHlNcd14oXCP79YRRyCHAD1o6ii_AjBeCcI65fq7nx0YBAz3-JosN26GWttliq3VCwvyh2jXpUIlETP0nTtxZuF_cLPH-UW9M7IX3ZyzUPjX9NAUSlv5Jh34HtFG8/s1600/P8270037.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSWbAxGwWBnkZIhuFHlNcd14oXCP79YRRyCHAD1o6ii_AjBeCcI65fq7nx0YBAz3-JosN26GWttliq3VCwvyh2jXpUIlETP0nTtxZuF_cLPH-UW9M7IX3ZyzUPjX9NAUSlv5Jh34HtFG8/s320/P8270037.jpg" width="320" /></a></div><br />
To join the inverted seat tube stub to the now-plumb end of the down tube, I decided to run the seat post through the seat tube and up into the down tube. I brushed the finish off the seat tube and drilled holes to allow for rosette welds, which would help join the seat post and tubes.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEseS5tHZu67zRdXE_oIQw0ZQ9HXfF6lUPYR1Ob6T3jNzvtPUUMwg7PjXoLN3tkuxya8OmJ4xYzaRqIkMnsxALDEObx8nP97wMtxNzttwKEx80TB6gYFg-AvudseeXTPA2V-Jr4ToIq2I/s1600/P8270043.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEseS5tHZu67zRdXE_oIQw0ZQ9HXfF6lUPYR1Ob6T3jNzvtPUUMwg7PjXoLN3tkuxya8OmJ4xYzaRqIkMnsxALDEObx8nP97wMtxNzttwKEx80TB6gYFg-AvudseeXTPA2V-Jr4ToIq2I/s320/P8270043.jpg" width="320" /></a></div><br />
With the seat tube installed (forcibly, with a mallet) it was ready to weld.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq8mM2nelb1ztF10alaHZjc4d4q2ILxjTpoY2iIbcP6covIHsIOMgNf_vRWBuq_3P8SvSqv1C_Wa2GVc3VlQnTWCpuMMoiFiFoP3rPf7iK8tbZ_HqJx6gfxYOLgOJ9-K_m7uXHfRvIRbo/s1600/P8270045.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq8mM2nelb1ztF10alaHZjc4d4q2ILxjTpoY2iIbcP6covIHsIOMgNf_vRWBuq_3P8SvSqv1C_Wa2GVc3VlQnTWCpuMMoiFiFoP3rPf7iK8tbZ_HqJx6gfxYOLgOJ9-K_m7uXHfRvIRbo/s320/P8270045.jpg" width="320" /></a></div><br />
It was a fussy business getting the alignment right, so that the deck was level and the correct height off the ground. When I was satisfied with it, I tack-welded it all together.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7uaxKb71crMVG1tRwHAwfSxeg8GJqj-xHPH_jnf0LQss_shZmuvBRcutVzRtUNGX0Z0jdBUqNfvPkD2WK2tdON4Pi1KUtu9k8Os3GFLDney9qclcuEuqnUKCqgadSGakRSW-nMe206qQ/s1600/P8270048.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7uaxKb71crMVG1tRwHAwfSxeg8GJqj-xHPH_jnf0LQss_shZmuvBRcutVzRtUNGX0Z0jdBUqNfvPkD2WK2tdON4Pi1KUtu9k8Os3GFLDney9qclcuEuqnUKCqgadSGakRSW-nMe206qQ/s320/P8270048.jpg" width="320" /></a></div><br />
The remaining challenge was to modify the stays to hold a smaller wheel from a child's bike and tack the whole thing together, which I'll show in the next post.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-65066811538681589352010-09-29T13:13:00.000-04:002010-09-29T13:13:22.820-04:00Building a cut-down bike scooter, part 1I had a very exciting commission this summer. My client had seen kids in Cuba riding kick scooters cut down from broken bicycles, and wanted one made. We didn't have any photos to work from, so I got to develop my own design.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjl2yPdlzOcDXoudlXM1ASfJ0XrfvlHrTnlQiAxkzMzUuEpSpH4ilbGOMz_bEiMD7G2ySsWIZgOGaXsok71u1gyckeMhuihkoz_tlkxTialTBmakaAchQ6CuwkgOcKOOb-s_WDluC8reT4/s1600/P9050022.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjl2yPdlzOcDXoudlXM1ASfJ0XrfvlHrTnlQiAxkzMzUuEpSpH4ilbGOMz_bEiMD7G2ySsWIZgOGaXsok71u1gyckeMhuihkoz_tlkxTialTBmakaAchQ6CuwkgOcKOOb-s_WDluC8reT4/s320/P9050022.jpg" /></a></div><br />
This is what I ended up building. It is lots of fun to ride! The deck is made of sprocket gears and sections of wheel rim, and the rear dropouts hold a wheel from a kids' bike.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHuj0a55Ffwk4tTXyCHdIBFIDzd8H7GqgK8ZMae-7zeLK-GRjxF__bwsc4SmCIapdyTf364F5KtKQ1PL9Hr9n2jQkYmpkfxYMj8hdmpIbAnHkG5iT8tx2RsyqkTvKomW-NHJAJkaiOBGU/s1600/P8250004.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHuj0a55Ffwk4tTXyCHdIBFIDzd8H7GqgK8ZMae-7zeLK-GRjxF__bwsc4SmCIapdyTf364F5KtKQ1PL9Hr9n2jQkYmpkfxYMj8hdmpIbAnHkG5iT8tx2RsyqkTvKomW-NHJAJkaiOBGU/s320/P8250004.jpg" /></a></div><br />
<div style="margin-bottom: 0px; margin-left: 0px; margin-right: 0px; margin-top: 0px;">I watched for discarded mountain bikes with sturdy frames, and picked up a bike with partially rectangular tubes and front shocks, but no front wheel. I pulled a decent wheel from another bike and swapped in a set of cruiser handlebars.</div><div><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivsOsenLhk5zuuO1OoNtFWKR0N1y7EQFpxe4Vc7RhO_s8AD1MfXWjMq_2-A1OGlfhJ328Mw-eNmcnnSHAQgLlLhvjCJ-_PE5JqS-zsEnekPjaMuWHfPqw3gqX6f0rkwvNskANnbMND960/s1600/P8250007.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivsOsenLhk5zuuO1OoNtFWKR0N1y7EQFpxe4Vc7RhO_s8AD1MfXWjMq_2-A1OGlfhJ328Mw-eNmcnnSHAQgLlLhvjCJ-_PE5JqS-zsEnekPjaMuWHfPqw3gqX6f0rkwvNskANnbMND960/s320/P8250007.jpg" /></a></div><br />
I use a cutting disc in an angle grinder to cut bikes apart. To start, I separated the top tube from the head tube, and the down tube from the bottom bracket. That left the pieces seen above: the front shocks, head tube, and angled down tube, and the rest of the bike.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_f9m0iZ1uZy_7FhwOn0MgY6y3nj1DC1TqrcaZK5BrztO3MpO2B5ERJs6zsLSg-Rd-87NyzsWT0nCo5-f15d7nGB5dgv3wn_hguCsFDnV_6iQ4PYJ7SItpoErEs5rrosPJlnDVYRx_re4/s1600/P8250010.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_f9m0iZ1uZy_7FhwOn0MgY6y3nj1DC1TqrcaZK5BrztO3MpO2B5ERJs6zsLSg-Rd-87NyzsWT0nCo5-f15d7nGB5dgv3wn_hguCsFDnV_6iQ4PYJ7SItpoErEs5rrosPJlnDVYRx_re4/s320/P8250010.jpg" /></a></div><br />
The plan was to wrap the down tube around the wheel so that it is ultimately plumb, straight up and down. I opted to cut out wedges and cold-bend the tubing before welding the bends shut again.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3462GaUyyzv3x9vycVx3Opy3g702uLIbInCtadIG6QEkD6UBpkZ8YX4X1c6RZtxLe84TLId1lmrqT8apZ6GJmv8rbKJYzH71-3yBtuHKOQHTXs8sxeMkOQqBqhqJNxDj961RQe_FXH3Y/s1600/P8250013.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3462GaUyyzv3x9vycVx3Opy3g702uLIbInCtadIG6QEkD6UBpkZ8YX4X1c6RZtxLe84TLId1lmrqT8apZ6GJmv8rbKJYzH71-3yBtuHKOQHTXs8sxeMkOQqBqhqJNxDj961RQe_FXH3Y/s320/P8250013.jpg" /></a></div><br />
In the photo above, I've marked the wedge that I intend to remove with soapstone.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5ZuzfsQ2Z8Azey6MVlBrlgsKyDBfTjVVdFmvYc5QSV3cwhNOzPOQ48OnlDWSk6Vt4eDG5QV5X25jfFoRO0NmX8WaYZLrRsHBV5Jjt2FhdBmh5MxOOM-HViOJQpio0Kn88RqPduA6K9Ls/s1600/P8250016.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5ZuzfsQ2Z8Azey6MVlBrlgsKyDBfTjVVdFmvYc5QSV3cwhNOzPOQ48OnlDWSk6Vt4eDG5QV5X25jfFoRO0NmX8WaYZLrRsHBV5Jjt2FhdBmh5MxOOM-HViOJQpio0Kn88RqPduA6K9Ls/s320/P8250016.jpg" /></a></div><br />
After cutting out the wedge, I was able to bend the remaining tube like a hinge, closing the wedge to a weldable line.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3SC4aTdbgfIjAnBueASpG8PwK1AzBzTqzi394cxVzRW6tm8L8ylDos8QVuelnPmJeWy8MFwHLWsubVZAyaoOat4Ivo4X5C42b140AIjKHgv5kvGQzg2125k4dGGi4FvbodxfmnbzoP_Y/s1600/P8250017.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3SC4aTdbgfIjAnBueASpG8PwK1AzBzTqzi394cxVzRW6tm8L8ylDos8QVuelnPmJeWy8MFwHLWsubVZAyaoOat4Ivo4X5C42b140AIjKHgv5kvGQzg2125k4dGGi4FvbodxfmnbzoP_Y/s320/P8250017.jpg" /></a></div><br />
Here's a close-up.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH-N1lvuG2xTJ7VUNwW7-BI5Z6hyr7SXVXVWrRJ4WRzaD6R86n1bGN6of2r5CE3cBHmdYCTbw37ysxS9ODB-1cnukeV9C-TiubkETbI3S94ueIsUXAWUZPX21iMuNASY8613KiS4du_U4/s1600/P8260019.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH-N1lvuG2xTJ7VUNwW7-BI5Z6hyr7SXVXVWrRJ4WRzaD6R86n1bGN6of2r5CE3cBHmdYCTbw37ysxS9ODB-1cnukeV9C-TiubkETbI3S94ueIsUXAWUZPX21iMuNASY8613KiS4du_U4/s320/P8260019.jpg" /></a></div><br />
I removed a similar wedge at the second bend in the down tube, so that the last segment will be plumb. Then I removed the finish in the area of the welds and tack-welded the bends closed.<br />
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The plumb section of down tube did not come nearly close enough to the ground to support the deck, so the next step was to find a way to extend it (and hold the rest of the scooter up).Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-17495698802024138462010-09-23T07:17:00.000-04:002010-09-23T07:17:27.324-04:00Turning a bark-edged bangleI prepared a stack of bangle blanks <a href="http://hardwareaesthetic.blogspot.com/2010/02/preparing-blanks-for-bangles.html">a while ago</a>. This time I chose the interesting bark-edged one on top.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj33HS37q5INKWY-PO1w8Ffr6yNP-68VLqFqWhLuly8Zqv6dYGDdznYjSFXhxn5twWDz65Unh3wtGQgWzto7vUU2jmn_BAzID8HV5U_TfjQlMh3udPLIFGL6MgyFEQUt-sxFl9N_EFdCY8/s1600/IMG_0846.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj33HS37q5INKWY-PO1w8Ffr6yNP-68VLqFqWhLuly8Zqv6dYGDdznYjSFXhxn5twWDz65Unh3wtGQgWzto7vUU2jmn_BAzID8HV5U_TfjQlMh3udPLIFGL6MgyFEQUt-sxFl9N_EFdCY8/s320/IMG_0846.jpg" /></a></div><br />
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It's always best, but I find that to avoid knocking bits of bark off as I turn, I have to keep the gouge very sharp and the cuts shallow. The bark itself dulls the gouge quickly, so there's more sharpening involved. But it's worth it.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCPcfeHVrKorYOj0CzQNpCUujWJmg76vLjqi-7IU0BOxuF_xFl0UcWTSrRLeeZr7jhicVV6DFQ4ukNBiYn61Uq5BQKNr51UVTOTILhrcdyaNjClqRTTOe2tpQTnkCCJE-zt5JtNXenXF8/s1600/IMG_0868.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCPcfeHVrKorYOj0CzQNpCUujWJmg76vLjqi-7IU0BOxuF_xFl0UcWTSrRLeeZr7jhicVV6DFQ4ukNBiYn61Uq5BQKNr51UVTOTILhrcdyaNjClqRTTOe2tpQTnkCCJE-zt5JtNXenXF8/s320/IMG_0868.jpg" /></a></div><br />
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Once the shape is developed and the exterior rough-sanded on the lathe, I remove the core with the same hole saw that I used to mark it initially.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid0oe33fMZEzp8_V3Ux9ZUcQw7D6FZTKXFWIcPEzjT869vIu-i2kE1uaOnZXC-iYuETix3xHjvOzcTPvhy3R8V_neiKzMZkcyd6XKuqrQdykHx7fgKJGgLWb7RQBvu8ZXubzoaeOERzhM/s1600/IMG_0871.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid0oe33fMZEzp8_V3Ux9ZUcQw7D6FZTKXFWIcPEzjT869vIu-i2kE1uaOnZXC-iYuETix3xHjvOzcTPvhy3R8V_neiKzMZkcyd6XKuqrQdykHx7fgKJGgLWb7RQBvu8ZXubzoaeOERzhM/s320/IMG_0871.jpg" /></a></div><br />
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After some careful sanding and a walnut oil finish, here's the bangle! It sold quickly.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrkYR8qZZrCJTV1k9ujwi6SIFz6yCpheXypaFs20-nFG5u5uMM_BB5l2_OzEnq2RzETxgPUd3ugS9sMOjE84i7i5Fql0YDhJmmcvVwkiUi3ML4N94HlQvL39fO__F1GZf8Wuz3oRupZzU/s1600/IMG_0894.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrkYR8qZZrCJTV1k9ujwi6SIFz6yCpheXypaFs20-nFG5u5uMM_BB5l2_OzEnq2RzETxgPUd3ugS9sMOjE84i7i5Fql0YDhJmmcvVwkiUi3ML4N94HlQvL39fO__F1GZf8Wuz3oRupZzU/s320/IMG_0894.jpg" /></a></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-36729210167320978572010-09-14T19:29:00.000-04:002010-09-14T19:29:25.263-04:00Forging sturdy toggle claspsI've had trouble recently with storebought clasps breaking, especially on my bicycle chain bracelets. The standard lobster clasps are difficult to operate at best, but they are also too brittle and easily snapped. Toggle clasps (rod-and-loop) are easier to use but aren't any stronger. So I decided to try making my own.<br />
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I don't have an actual coal forge, and my anvil is tiny, but the torch is up to the heating job and I don't need much of an anvil table for this work. I get a finish nail up to workable temperature, just red-hot, and then hammer the centre section flat.<br />
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In the photo above you can see an unmolested finish nail at right. The rest have been heated, hammered, and quenched in a little tub of cold water.<br />
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After grinding and filing the ends smooth and dull, I drill out the centre to take a small lead of cord.<br />
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The loops of the toggle clasps are made of heavy wire. I use standard jeweler's wire-bending tools to create one large loop.<br />
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Then, a smaller tool to make a smaller loop in a figure 8. It takes some oomph to bend the heavy wire in a tight radius like this.<br />
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Then I use a hacksaw to cut the loops free of the wire bale. Side cutters or snips would deform the circles too much.<br />
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The free ends are on opposite sides of the loop.<br />
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For these, I heat them closer to the melting point. After red, the metal turns orange and then bright yellow, which is where I want it for forge-welding the free ends closed. When it's hot enough, I lay it on the anvil and hammer the overlaps into each other so that the whole loop lies flat.<br />
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This is what the finished clasp looks like on a choker. More fun than shopping for findings, much stronger than commercial clasps, and appropriately grungy and rough in appearance. And easy to close and remove.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-48488116718931031312010-09-08T09:04:00.000-04:002010-09-08T09:04:02.483-04:00Finishing a bicycle frame keyboard standHaving found that a single bicycle frame is readily cut down into one side of a support stand, I chose another frame and prepared it in a similar way.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb9S9bQkUgjvd6VKAStkcCnN3BNbEjSqzS4-WjGGVjhvwRz9i55vT7GIj8DSo_PkiwoFv02mSghjYX2KwqPabb-mz2M9Q2K5ze0tDLggW6SmFxcTHQJL-2W2jJ8hmu9oCG9pHbI8jk2-I/s1600/P5100042.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb9S9bQkUgjvd6VKAStkcCnN3BNbEjSqzS4-WjGGVjhvwRz9i55vT7GIj8DSo_PkiwoFv02mSghjYX2KwqPabb-mz2M9Q2K5ze0tDLggW6SmFxcTHQJL-2W2jJ8hmu9oCG9pHbI8jk2-I/s320/P5100042.jpg" /></a></div><br />
It was a different size and of different geometry, so I took some time to ensure that the top supports were level.<br />
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Can't ask for better than that.<br />
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When the alignment was right, I clamped and welded the base.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVQvffJmOzK4QPku5urNyG48ifUyKAEPXX5yAXa9dqEQX3drtYkltCwfxUVpGBrphBfbQRcHugTVTJDw8rO2Hm6J7U8RheKDRbeO6jNRomSPpo4QdCh8BRgq9HrcpyTDjQJVD37KEFn1w/s1600/P5110054.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVQvffJmOzK4QPku5urNyG48ifUyKAEPXX5yAXa9dqEQX3drtYkltCwfxUVpGBrphBfbQRcHugTVTJDw8rO2Hm6J7U8RheKDRbeO6jNRomSPpo4QdCh8BRgq9HrcpyTDjQJVD37KEFn1w/s320/P5110054.jpg" /></a></div><br />
The next step was to commit to the placement of the lower support tubes. I aligned the first so that it was both level itself and potentially level with its counterpart on the other frame. (There's a limited range of adjustment.)<br />
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Once I had tack-welded that support in place, I leveled across to the second frame and positioned its lower support to match. In the photo above, you can see that the lower support tube on the second frame hasn't been cut and is still crossing the angled vertical tube.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8tD2mjJBQvPKbLvnGd4Pkwtfpy58AuPTuChQJ1rso-ChHh6Bzx27sV-J0tSXVTAN4i3rpQ32hMW4MVRUaBG5Vyo_N9UQeNzgmMeVaReScc-aaJ6CUaC9y3Ann2W190h_I3AU1Crt00Is/s1600/P5110063.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8tD2mjJBQvPKbLvnGd4Pkwtfpy58AuPTuChQJ1rso-ChHh6Bzx27sV-J0tSXVTAN4i3rpQ32hMW4MVRUaBG5Vyo_N9UQeNzgmMeVaReScc-aaJ6CUaC9y3Ann2W190h_I3AU1Crt00Is/s320/P5110063.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div>And here are both sides of the stand, welded and ready for cleanup.<br />
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To keep the left and right support frames from toppling over if I get excited, they are fixed to a plywood base. I marked and drilled through fir support blocks and inserted axles to hold what were formerly the rear dropouts of the bicycles. The frames just slide over the axles and then rotate up into position, firmly attached.<br />
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I positioned my pedals where I like them, and nailed thin strips of wood in place to hold them there. It's nice that they don't slide around now.<br />
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To clean up the look of the stand, I wire-brushed all of the old finish off the frames.<br />
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Down to bare metal, I like their look a lot more. I coated all of the metal parts with wax as a basic rust barrier, although I will have to keep that finish maintained as it is not very durable.<br />
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With a couple of coats of black stain on the plywood base, the stand is complete. Custom fit to me and my keyboards, interesting to look at, and more comfortable to play at.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI0kGQ9mZudL1VSxu0f_VO6FD7Z4BFrLUUfKyjM-wd1zsyeSfN-1IQAPHUdhQKP87GAcFIHaBXWzSRYIvsSN00pDnywLtwVZMvyGV0HyI9DXrV9RhcwqyxFyzOse2FnTUALk5C6vnCUuc/s1600/P5170016.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI0kGQ9mZudL1VSxu0f_VO6FD7Z4BFrLUUfKyjM-wd1zsyeSfN-1IQAPHUdhQKP87GAcFIHaBXWzSRYIvsSN00pDnywLtwVZMvyGV0HyI9DXrV9RhcwqyxFyzOse2FnTUALk5C6vnCUuc/s320/P5170016.jpg" /></a></div><br />
I also like the fact that, other than the hunk of plywood I had lying around, the stand is made of abandoned and recycled parts.<br />
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Similar instrument and other stands and tables are available by custom order from my shop. If you're interested in knowing more, please contact me at <a href="mailto:david@hardwareaesthetic.com">david@hardwareaesthetic.com</a>.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-50202647396633387032010-09-01T10:31:00.000-04:002010-09-01T10:31:29.123-04:00Welding a bicycle frame instrument standI play keyboards in a Tom Petty tribute band called Full Moon Fever (<a href="http://fullmoonfever.ca/">fullmoonfever.ca</a>). I don't like my commercial keyboard stand -- I play seated, and it has an X-shape that prevents my knees from fitting below my instruments.<br />
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I also have a lot of bicycle frames lying around, stripped of their parts for jewelry and sculpture. I thought I'd use the tubing to weld a custom keyboard stand.<br />
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The front forks fit into the seat tube, and if the forks become the base of the stand, then the down tube becomes the top support, and the height to it is just about right. Convenient!<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg4G5TdYsuFDgMP27wZZ4MLzKm-ozj7-IrBHwdJJKtu-1hOW2OYILl_8Q_yAWgGdM0yBb3H0O04NGogZLfofS9UK_gnDp2_JmxBTnFD6EeXz62tyJ9TuozIkFLDPoG5ulvbuQuaGDglsM/s1600/P5080012.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg4G5TdYsuFDgMP27wZZ4MLzKm-ozj7-IrBHwdJJKtu-1hOW2OYILl_8Q_yAWgGdM0yBb3H0O04NGogZLfofS9UK_gnDp2_JmxBTnFD6EeXz62tyJ9TuozIkFLDPoG5ulvbuQuaGDglsM/s320/P5080012.jpg" /></a></div><br />
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I marked the down tube to be long enough to hold my organ, and cut the top tube long enough to support my piano and reach back to the seat tube to be welded in place.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQH3HRNhYPdhe6_DIdiEDAcXtKo3bP-MHesTHtxtOEuxVKkwX1wjUTYBvSi7_ntXHF_HHDm3Xo49ylvtouwFLMTUIkh26T5L1AO_W1kh7zwE9vCwYsUE2ElcoS1ylNibDjnCa4iy-HUKk/s1600/P5090017.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQH3HRNhYPdhe6_DIdiEDAcXtKo3bP-MHesTHtxtOEuxVKkwX1wjUTYBvSi7_ntXHF_HHDm3Xo49ylvtouwFLMTUIkh26T5L1AO_W1kh7zwE9vCwYsUE2ElcoS1ylNibDjnCa4iy-HUKk/s320/P5090017.jpg" /></a></div><br />
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The freed section of frame consists of the remainder of the down tube, the support section of top tube, and the head tube joining them. I flipped it over and checked the fit. So far so good.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMzeSX9edxSh9TLIgIira0__9AwenD6Wp1bLqgIrjl7b7-vYGAg6Lo2rkGg5Pgsqux2vVRF43x1eKSJfF1M1Wuor-FgRdLR_7cma992C3DG24ePoxiEVlH0yTGPeHGHvWbkXZ2wWywH9s/s1600/P5090020.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMzeSX9edxSh9TLIgIira0__9AwenD6Wp1bLqgIrjl7b7-vYGAg6Lo2rkGg5Pgsqux2vVRF43x1eKSJfF1M1Wuor-FgRdLR_7cma992C3DG24ePoxiEVlH0yTGPeHGHvWbkXZ2wWywH9s/s320/P5090020.jpg" /></a></div><br />
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To complete the base of the stand, I cut the rear stays and dropouts free of the rest of the frame, and moved them down to meet the front forks.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3f1m036q9C8w-B5ofhFtdIjWjtRtBJh4eHdtNuKe5xWB1vbbcrnCfQtIRfLuspMdiFsIcPW4iA4NTA0aVH1EZy3pPpvW0kJI3eN-S4lDxKpdAs9E7Z8Iv_z1KhQL9xHnwcDkwvdXkpiM/s1600/P5090021.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3f1m036q9C8w-B5ofhFtdIjWjtRtBJh4eHdtNuKe5xWB1vbbcrnCfQtIRfLuspMdiFsIcPW4iA4NTA0aVH1EZy3pPpvW0kJI3eN-S4lDxKpdAs9E7Z8Iv_z1KhQL9xHnwcDkwvdXkpiM/s320/P5090021.jpg" /></a></div><br />
I marked the length and angle of the top tube and cut it to meet the seat tube.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjauTGqyyXkkoFNCAKxmmF0lzeNiYU5e1uv7XbR9zoQWM-Ls2Y3FV_6OSgBb8LNH2woyiytGupuFAotPyaAR_J1W0xb36Zwv8lA203awMXgURIqjyZfifPi4PqqeQfcm4yChGVzn6PzcZo/s1600/P5090023.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjauTGqyyXkkoFNCAKxmmF0lzeNiYU5e1uv7XbR9zoQWM-Ls2Y3FV_6OSgBb8LNH2woyiytGupuFAotPyaAR_J1W0xb36Zwv8lA203awMXgURIqjyZfifPi4PqqeQfcm4yChGVzn6PzcZo/s320/P5090023.jpg" /></a></div><br />
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The section of down tube still attached to the head tube slides nicely over the remaining section of top tube. So there's the basic shape: standing on the dropouts, with a long support for the lower keyboard and a shorter one for the top.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL9N0e8sqn1lfawjLAvR5Qjrh63Y4Ia4cUn4RVQ9LO5cT4lf5Ki64AO_E2i-_WfhPGgo8J-Po7zdjjQHq-8Kpep0-J8dc5piOTrVfU91aFbLob0J9ScE2I8c549qW9Q44m5fEl3rWS2RQ/s1600/P5090024.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL9N0e8sqn1lfawjLAvR5Qjrh63Y4Ia4cUn4RVQ9LO5cT4lf5Ki64AO_E2i-_WfhPGgo8J-Po7zdjjQHq-8Kpep0-J8dc5piOTrVfU91aFbLob0J9ScE2I8c549qW9Q44m5fEl3rWS2RQ/s320/P5090024.jpg" /></a></div><br />
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With the seat stays cut to meet the front forks and clamped in place, it stands up and looks about right.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixKisSreZ0nG94EZV0yJikhnt7zGkAMBzYW3vWcx64DeeDdCo-rMC8fUvhtT93EnYxsj1jmp-r1qCm4E0eSJxmE2CQSdht2SJ04hfZet1k4_Kvb4eov-9VttARDaaB5iStd2G-RQC6m_g/s1600/P5090026.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixKisSreZ0nG94EZV0yJikhnt7zGkAMBzYW3vWcx64DeeDdCo-rMC8fUvhtT93EnYxsj1jmp-r1qCm4E0eSJxmE2CQSdht2SJ04hfZet1k4_Kvb4eov-9VttARDaaB5iStd2G-RQC6m_g/s320/P5090026.jpg" /></a></div><br />
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I wire brushed all of the joints free of finish, then welded everything but the section that will hold the lower keyboard. I want to reserve the option to adjust its fit later when I make the other side of the stand from another bike frame.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhijtMNoVoVTDKQOEHdQ6mju03KeOr8GuOiV67Fb-eW5duEge96Z8qat5A9QnALJ-LQW5FfMP3b_JOOQsw0xdc0TT4GXVGCH9-_XzWbLwUmHqqRkG-Gi6xewRP78drli8m1t6IulMlcnI/s1600/P5090027.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhijtMNoVoVTDKQOEHdQ6mju03KeOr8GuOiV67Fb-eW5duEge96Z8qat5A9QnALJ-LQW5FfMP3b_JOOQsw0xdc0TT4GXVGCH9-_XzWbLwUmHqqRkG-Gi6xewRP78drli8m1t6IulMlcnI/s320/P5090027.jpg" /></a></div><br />
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I tried a test fit with the left half of my keyboards still supported by the commercial stand. It works!<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUDXEN4GXLWimfCEz18i4ExUQmG6TbiCybhTkMjpVF5xZh5ods_NAlUTCX0ptiEKyuU0OviPIBZGIm2D2arnJdxbs-CqBkprqT70b_3AMUrTcLdUoVJFyDhA3XIO3sZLCXeKfk3B6xgks/s1600/P5090029.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUDXEN4GXLWimfCEz18i4ExUQmG6TbiCybhTkMjpVF5xZh5ods_NAlUTCX0ptiEKyuU0OviPIBZGIm2D2arnJdxbs-CqBkprqT70b_3AMUrTcLdUoVJFyDhA3XIO3sZLCXeKfk3B6xgks/s320/P5090029.jpg" /></a></div><br />
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In the next post, I'll describe making the left side support like this one, and then a base and custom pedal board to hold it all together.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-54281995125522273102010-06-27T10:46:00.000-04:002010-06-27T10:46:08.930-04:00Welding a custom bike chain ringI had an interesting custom order recently, for a bicycle chain ring in a custom size. As a set of closed links, there's only one ring size possible with standard chain, and it's very small -- about 5 3/4. To make a custom size, I'd have to weld the links closed.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgF-iE7CphYaAXCJIU2iVGBEti8gCb1mu9vJaUKdg0DAg671zd3Ms_7SlJFkEgEDM7y8czVKVn61RgBuLgh0GGs-ggAd_zzm9CF-zy_HpfbVKM3r26I-Eg7I1w7HFzgUcjRTXsfZ1ONNWY/s1600/P5050033.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgF-iE7CphYaAXCJIU2iVGBEti8gCb1mu9vJaUKdg0DAg671zd3Ms_7SlJFkEgEDM7y8czVKVn61RgBuLgh0GGs-ggAd_zzm9CF-zy_HpfbVKM3r26I-Eg7I1w7HFzgUcjRTXsfZ1ONNWY/s320/P5050033.jpg" /></a></div><br />
I started by turning a sizing guide in a piece of 2x4, and then wrapped a length of chain around it to see where cuts would be needed.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4DAIoCc2-fEJ5yBTSeXMi310wmWvG-n_EjCAxZpARcInMSiFPgkXIcWc8nZ00UeBc27_RmOOaOCjSnTuNGqwGkijD_cK0-9b7pSRfkTQlqwu4ziLO6vO-JNikhNxHysRnNK7u18R69Kg/s1600/P5050037.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4DAIoCc2-fEJ5yBTSeXMi310wmWvG-n_EjCAxZpARcInMSiFPgkXIcWc8nZ00UeBc27_RmOOaOCjSnTuNGqwGkijD_cK0-9b7pSRfkTQlqwu4ziLO6vO-JNikhNxHysRnNK7u18R69Kg/s320/P5050037.jpg" /></a></div><br />
There was an excess section of inner link that was preventing the ring from closing around the form. I removed that material on the grinder until the ring could close, and then rounded off the corners.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuS7-0_rHdtI7dRT_2rPAI-GymI7k_CU5XfDvxNV-D94lA52glFun-50nyi8N1aVEBWKOH1OfIEzTfYoExb1JMcIFudIvoYCmvH6ufM5VEl2QLediMEqq1o0kQY2eWjGffjFSjXeRtnWQ/s1600/P5050038.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuS7-0_rHdtI7dRT_2rPAI-GymI7k_CU5XfDvxNV-D94lA52glFun-50nyi8N1aVEBWKOH1OfIEzTfYoExb1JMcIFudIvoYCmvH6ufM5VEl2QLediMEqq1o0kQY2eWjGffjFSjXeRtnWQ/s320/P5050038.jpg" /></a></div><br />
The next step was to remove part of the extra outer link, but leave a section in place to be welded. I cut it off with a hacksaw and checked the fit again.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHtruwFjoo6sdzgpWvcjiWZAJ9Niull0byFxKpHxsRR5p6r9K8j5cgvtoTAzC2_-FOPG5mtV2ZIGQvf8PQJ-g01zxqN9ITLEoKdWoRsn2PhSowiyu2qAKFNBCRCDrbnPt_MvoMEXkcSo0/s1600/P5050017.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHtruwFjoo6sdzgpWvcjiWZAJ9Niull0byFxKpHxsRR5p6r9K8j5cgvtoTAzC2_-FOPG5mtV2ZIGQvf8PQJ-g01zxqN9ITLEoKdWoRsn2PhSowiyu2qAKFNBCRCDrbnPt_MvoMEXkcSo0/s320/P5050017.jpg" /></a></div><br />
That's about right. I reshaped the cut edge of the outer link on the grinder before welding.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimyDRlxwzEy9nW9zDZwMywkcKEVZXZqzvzj032q8HmteFvD6t0eQFb6zwyP8A6O-zaPKhBOhgYuHjmoMix-ilaNcaFHyoOj8kKd61rxB8CqeMBhk2iq_rfiS5ydbW0Zl07V1cIe3bsM_Q/s1600/P5050020.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimyDRlxwzEy9nW9zDZwMywkcKEVZXZqzvzj032q8HmteFvD6t0eQFb6zwyP8A6O-zaPKhBOhgYuHjmoMix-ilaNcaFHyoOj8kKd61rxB8CqeMBhk2iq_rfiS5ydbW0Zl07V1cIe3bsM_Q/s320/P5050020.jpg" /></a></div><br />
Here is the custom ring, ready for welding.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAVOEkpkbDcvRdKp359HrZFKbT4taaum6QwLhWLjmbjablm3LWBW19taZkdKK3zor3Wv9vOWbXWywlxrn1D53Km-YFCvZTmF-9QKRIA6FV86EDKLE6TlWWyn3Rc11Ki94HzmhJ_T1GU5g/s1600/P5050023.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAVOEkpkbDcvRdKp359HrZFKbT4taaum6QwLhWLjmbjablm3LWBW19taZkdKK3zor3Wv9vOWbXWywlxrn1D53Km-YFCvZTmF-9QKRIA6FV86EDKLE6TlWWyn3Rc11Ki94HzmhJ_T1GU5g/s320/P5050023.jpg" /></a></div><br />
With the link welded closed at the correct angle, the ring is ready to wear.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEillJ3xubW0i9Uk0hdsQ9oWO93QSIVrogl7-EqZqLqfcTwz8uptgTbVBu6bQIA9j7FHQYZZ2O5bDK9KKUncgklc1TOFogGsh7fOKoeISI99lOO3mowIw-4U6MMKq5_9RZ6RnMkc_mzqkps/s1600/P5050027.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEillJ3xubW0i9Uk0hdsQ9oWO93QSIVrogl7-EqZqLqfcTwz8uptgTbVBu6bQIA9j7FHQYZZ2O5bDK9KKUncgklc1TOFogGsh7fOKoeISI99lOO3mowIw-4U6MMKq5_9RZ6RnMkc_mzqkps/s320/P5050027.jpg" /></a></div><br />
This one was too big for any of my fingers, but it made a good thumb ring.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC45pf_niC0piksj7x2Nw2-QcY81gK6GGwFgtOIGzrNhA6NcNeJ3z-uZj6-UX2ev9IDPZ-qJnfQ1bcbix_AozFBnyiC8ziDDwZPhRUQ0fgAVT_YICrBwQjntOqj0MIx_SZ3qC3HhggN0M/s1600/P5050024.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC45pf_niC0piksj7x2Nw2-QcY81gK6GGwFgtOIGzrNhA6NcNeJ3z-uZj6-UX2ev9IDPZ-qJnfQ1bcbix_AozFBnyiC8ziDDwZPhRUQ0fgAVT_YICrBwQjntOqj0MIx_SZ3qC3HhggN0M/s320/P5050024.jpg" /></a></div><br />
These rings are available made to order in my shop, here: <a href="http://www.etsy.com/listing/50296717/made-to-order-bicycle-chain-ring">hardwareaesthetic.etsy.com</a>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-38648180597905981472010-06-24T13:16:00.000-04:002010-06-24T13:16:06.382-04:00Prototyping a percussion instrument, continuedWith the top glued to the curved shell, I could try to tune the tongues. I started by relieving the hinge areas, which tends to lower the pitch and improve the tone at the expense of volume. I used a chisel to pare away material.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf01JZkqbS_MSSYeJo_aBWNm2MaWkzLMBwfQGy9MAzO6EFyTetjvPVM7HBFpx3p6XAIw9Xo7IN0NVHrx-x1YkBFpDKIg4tP585-W3knKOLupLiUF1q2ItMLVYuX4MqhWsGy9NM3q3BIBI/s1600/IMG_0034.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf01JZkqbS_MSSYeJo_aBWNm2MaWkzLMBwfQGy9MAzO6EFyTetjvPVM7HBFpx3p6XAIw9Xo7IN0NVHrx-x1YkBFpDKIg4tP585-W3knKOLupLiUF1q2ItMLVYuX4MqhWsGy9NM3q3BIBI/s320/IMG_0034.jpg" /></a></div><br />
It went too easily, and I removed too much material from the hinge of several tongues. Wanting to raise their pitch, I also removed some material from the ends and edges. It worked to raise the pitch, but also made the pitch less specific and the tone more hollow. So there's a technique to avoid.<br />
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I continued to refine the sound as well as I could, and then cut a bottom from a handy piece of finish plywood, too thick to resonate well but enough for a proof of concept.<br />
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I glued the bottom to the assembly.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFf5LbQDG8BJbHMjsZtYBIrpxygOFDz4ZRDrGMtuYx55wREZXkzQ5l1Es1qR_ow1d5rYoyKYSc6S9SVn1wB8n5YNTUqTBcToKodC5eTd80N8xey1qQMbgTDWMBsu1wka3uhbaP95AbuGk/s1600/IMG_0260.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFf5LbQDG8BJbHMjsZtYBIrpxygOFDz4ZRDrGMtuYx55wREZXkzQ5l1Es1qR_ow1d5rYoyKYSc6S9SVn1wB8n5YNTUqTBcToKodC5eTd80N8xey1qQMbgTDWMBsu1wka3uhbaP95AbuGk/s320/IMG_0260.jpg" /></a></div><br />
When the glue dried, I made a pass around the bottom with a flush-trimming router bit to bring it in line with the shell, and then played it a bit with superball mallets.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9rkdaaCnC5GDUC9IeWM8mP7qtEqYi3g0GfMxWyrlXYLAXlByI8v2j9Nw7Y_Fo_5BOJZeo_8wco5ARlaYo-bMASWZ40XKFC-PE8izAPZ6iv34IchaQkIuy1BKhVlRqn-LGL0ORRAB60Hg/s1600/IMG_0269.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9rkdaaCnC5GDUC9IeWM8mP7qtEqYi3g0GfMxWyrlXYLAXlByI8v2j9Nw7Y_Fo_5BOJZeo_8wco5ARlaYo-bMASWZ40XKFC-PE8izAPZ6iv34IchaQkIuy1BKhVlRqn-LGL0ORRAB60Hg/s320/IMG_0269.jpg" /></a></div><br />
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So how does it sound? Well, promising at best. I plan to make another at some point and correct these problems:<br />
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<ul><li>Tune and free the hinges cautiously, and avoid trimming the ends or edges of the tongues.</li>
<li>Make a shell that resonates. The kerfed sides of this one are effective sound-deadeners.</li>
<li>Use a thin, solid back that can resonate.</li>
</ul><br />
When I make those improvements, it will be easier to tell whether this is a dead end or a promising direction. I'm still interested to find out.Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-79842320511881430952010-03-23T06:57:00.000-04:002010-03-23T06:57:24.392-04:00Prototyping a percussion instrumentI had an idea a while ago. I remember seeing an instructional video in which Bill Bruford was playing a complex rolling pattern between his toms and a tongue drum placed on his snare. For clarity, a tongue drum (sometimes called a slit drum) usually looks something like this. You've seen them.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHAdznJ_wlrhJjsol9d70LlSsLP8lfUWMO1JgfR6EdNZmkkYKkjFiMAzt0GlvNc9mZ-AXkwBJWnLrdvGnzOVZh7VbhhZw90-047SU6t5B48MiGFTMc29ygPwdfoW22AShnU7QHLLtuW00/s1600-h/tongue-drum.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHAdznJ_wlrhJjsol9d70LlSsLP8lfUWMO1JgfR6EdNZmkkYKkjFiMAzt0GlvNc9mZ-AXkwBJWnLrdvGnzOVZh7VbhhZw90-047SU6t5B48MiGFTMc29ygPwdfoW22AShnU7QHLLtuW00/s320/tongue-drum.jpg" width="320" /></a></div><br />
I thought it would be cool to make a circular tongue drum. I played with a number of configurations of rectangular tongues, but finally realized that the shape was calling for a radial arrangement of wedge-shaped tongues instead. Like this.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimYwg1d5rrh6I9rDWweZes9pE5v6ZJUqDcRsS1HW57Ky8eBMSJE6-aMdfCNxki_fjhoo40STrg88VEKiEZvMGXnrUtv7s9iI4euAQ4NDh8nCpP7fLEoF0qRMkp83xA1WSFGAOOCb71Ce8/s1600-h/skt.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimYwg1d5rrh6I9rDWweZes9pE5v6ZJUqDcRsS1HW57Ky8eBMSJE6-aMdfCNxki_fjhoo40STrg88VEKiEZvMGXnrUtv7s9iI4euAQ4NDh8nCpP7fLEoF0qRMkp83xA1WSFGAOOCb71Ce8/s320/skt.jpg" /></a></div><br />
I have a lot of baltic birch plywood around from cabinet projects, and so I took a first pass at a prototype using one of those panels.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF3h6aTLtXtHP4DmEWCWwDVBMjpuS-dmAFuekeHqFENJ7Sx8Xcmm0s5S0ayci6jG3Scr9Q1AObW8gpFSdqau7TOGm4hlBPBYp8Jyubb3Uif8gjlc-SU4XFp8dYcQMfVUv3KZZQIgqaXY4/s1600-h/IMG_9816.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF3h6aTLtXtHP4DmEWCWwDVBMjpuS-dmAFuekeHqFENJ7Sx8Xcmm0s5S0ayci6jG3Scr9Q1AObW8gpFSdqau7TOGm4hlBPBYp8Jyubb3Uif8gjlc-SU4XFp8dYcQMfVUv3KZZQIgqaXY4/s320/IMG_9816.jpg" /></a></div><br />
To cut the interior kerfs and allow the tongues to vibrate, I drilled through at the endpoints of the lines and threaded a scrollsaw blade through the hole.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL6s3XzYzJmSJu3VzFw1tu2P6_p__iJ8kVHlRvunvNi9Vi2JswM-th0thXbyDgMOGmTQ6V8kMTSSJpV2zEaOk6YtfhEw3IbwghE0vfda9Rd9wj6NCFnlIdFnlaFHVLcwKGmuYYvTRMoyo/s1600-h/IMG_9829.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL6s3XzYzJmSJu3VzFw1tu2P6_p__iJ8kVHlRvunvNi9Vi2JswM-th0thXbyDgMOGmTQ6V8kMTSSJpV2zEaOk6YtfhEw3IbwghE0vfda9Rd9wj6NCFnlIdFnlaFHVLcwKGmuYYvTRMoyo/s320/IMG_9829.jpg" /></a></div><br />
Once the tongues were cut, I cut outside the diameter mark on the bandsaw to complete the rough top. My scrollsaw technique is very rusty, and those inside cuts aren't up to production quality. Better to make the mistakes on the prototype.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwWkiapWd8gXI4jG33o-1pKSKceheLHSoWvlvVhZrzIAVb7Yq3ju3gO_52nAr2lJ7iY4_76n_TGrEKSjV_scf5gFK0-Ims__RD6CGoOl0PW8VKRS9_kd7NFdjBOTwXfWmIwBoC4yfy1ug/s1600-h/IMG_9836.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwWkiapWd8gXI4jG33o-1pKSKceheLHSoWvlvVhZrzIAVb7Yq3ju3gO_52nAr2lJ7iY4_76n_TGrEKSjV_scf5gFK0-Ims__RD6CGoOl0PW8VKRS9_kd7NFdjBOTwXfWmIwBoC4yfy1ug/s320/IMG_9836.jpg" /></a></div><br />
I thought I would try pulling a strip of the plywood around the radius by kerfing its backside every half inch.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjo3RdiGuNEEZkRXmLcNJ4Dmi3nFXvtu0q_7Ufvs2vrYsSgpffKoSwOAxrxytX7DOmyCDo2s7ZchxhSgGbyrck32pPRmRlMZ06HG3PD2XEL2e6eJuQHiiSx45WORMtzaFoZwfxSciHEsNs/s1600-h/IMG_9838.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjo3RdiGuNEEZkRXmLcNJ4Dmi3nFXvtu0q_7Ufvs2vrYsSgpffKoSwOAxrxytX7DOmyCDo2s7ZchxhSgGbyrck32pPRmRlMZ06HG3PD2XEL2e6eJuQHiiSx45WORMtzaFoZwfxSciHEsNs/s320/IMG_9838.jpg" /></a></div><br />
To cut the regular kerf spacing quickly, I hacked a quick jig onto the tablesaw mitre gauge.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMzQdzcudITZQgqZfum07WgNOzBgNhmWmCfb1ln34gvoxyTB3TClqHMyi0mtAEEk4vpbvgPY4AGtDgY4uW7spPUUsJo7Urj1tN59Z3Rhr4BpLhqecxYfTtlNko8GecyX2lIKiMfb1H68E/s1600-h/IMG_9844.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMzQdzcudITZQgqZfum07WgNOzBgNhmWmCfb1ln34gvoxyTB3TClqHMyi0mtAEEk4vpbvgPY4AGtDgY4uW7spPUUsJo7Urj1tN59Z3Rhr4BpLhqecxYfTtlNko8GecyX2lIKiMfb1H68E/s320/IMG_9844.jpg" /></a></div><br />
That's a fat roofing nail, nearly a full kerf thick, with its head cut off. Each cut kerf fits over the nail to position the next pass. Very quick, very accurate.<br />
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I used the waste from the top as a clamping form to glue the side closed in a rough circle. I had counted on the material curving evenly, but of course it did no such thing.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivhOHMMd3q4akRtDphSycSjqXLyBf5lu3wy1-de5mK00kQboYjhcfegjMy3KA2gUPK8NKf_f_UWd5bVRY93yHUarRhiBDajlDz5sFPHjYMHF8ArCVLyUsk9V6QmyVJxaRq8OmA5A7ip5w/s1600-h/IMG_9863.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivhOHMMd3q4akRtDphSycSjqXLyBf5lu3wy1-de5mK00kQboYjhcfegjMy3KA2gUPK8NKf_f_UWd5bVRY93yHUarRhiBDajlDz5sFPHjYMHF8ArCVLyUsk9V6QmyVJxaRq8OmA5A7ip5w/s320/IMG_9863.jpg" /></a></div><br />
To try to bring it into round, I cut some spacers and arranged them inside. It helped, but not enough.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbu9u5IXuPAkb0SgfrniYNkOLaSUUe6xFNcNcGNk_Mjr4r4eAgtrrtRadAATcg1TXqMYf8TizciDjG6C550b3fFGrqmBirDG8CgFK7H52PpsDi_YZsIJpnWEEnjEc8jXt_tlQDrG4NbTk/s1600-h/IMG_9867.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbu9u5IXuPAkb0SgfrniYNkOLaSUUe6xFNcNcGNk_Mjr4r4eAgtrrtRadAATcg1TXqMYf8TizciDjG6C550b3fFGrqmBirDG8CgFK7H52PpsDi_YZsIJpnWEEnjEc8jXt_tlQDrG4NbTk/s320/IMG_9867.jpg" /></a></div><br />
I glued the top to the side while it was still clamped to the form.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBcChG3Y6Jq65etY0ouW18SF6aBcBG-wQvUyFWVWoUc1JEqSYcQkfiTG3RWEROWNltJ1Ngav0SoSfzo3nu-hoQrO7s9mzl4FVauZOOB0pBXjWj6IfLHRcI-w4JKQon_PhfB9DxM9DhNZE/s1600-h/IMG_9875.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBcChG3Y6Jq65etY0ouW18SF6aBcBG-wQvUyFWVWoUc1JEqSYcQkfiTG3RWEROWNltJ1Ngav0SoSfzo3nu-hoQrO7s9mzl4FVauZOOB0pBXjWj6IfLHRcI-w4JKQon_PhfB9DxM9DhNZE/s320/IMG_9875.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW9cJMuDaeKV0qlnfqzcRLNyQxY5CVLv1pYi6bknuDK3Jx8VIBhQvsXKQluTZrFYuZGBa3tiUAd2t5mGxWLxqKAtyaHubBYOnMz5zmDIbsNMLorubI5bXcOdDJTNPAHr3W20R1MgUIYak/s1600-h/IMG_9878.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW9cJMuDaeKV0qlnfqzcRLNyQxY5CVLv1pYi6bknuDK3Jx8VIBhQvsXKQluTZrFYuZGBa3tiUAd2t5mGxWLxqKAtyaHubBYOnMz5zmDIbsNMLorubI5bXcOdDJTNPAHr3W20R1MgUIYak/s320/IMG_9878.jpg" /></a></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-7233480858311498152010-03-01T10:29:00.000-05:002010-03-01T10:29:14.931-05:00Finishing Bikes and Trees 3This is the workpiece in progress, and in pieces.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc2B5cG3NoggzNDL6VlA7xmT6EQrucTjaIG38Ox3xH3kY_aVfUYz42yZb0t2bazBDZf_Q8fUBs2WLdPSUDxMxxGa1Z6_rzazZeRyXO-FqQGEc7813V0Tbip7zJ8N_mTZfvXxHxNdaO0QA/s1600-h/IMG_0645.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc2B5cG3NoggzNDL6VlA7xmT6EQrucTjaIG38Ox3xH3kY_aVfUYz42yZb0t2bazBDZf_Q8fUBs2WLdPSUDxMxxGa1Z6_rzazZeRyXO-FqQGEc7813V0Tbip7zJ8N_mTZfvXxHxNdaO0QA/s320/IMG_0645.jpg" width="270" /></a></div><br />
And this is a closeup of the problematic foot. The deep scoring is from the chuck jaws, which I had previously clamped down on the base in frustration. The bowl had held securely, yes. But.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghiZYRGHI-ZrD-wScXuLGbre05xPOdxkETCdlP1xAme8hzoKTzONSv_2zByvkuGvAjH9uJbr5JnIR6A4fLLU4pA7cQroc6ZzqnkcsfhRV8NuNm4p4l1paDZ5UkV7F7ty5U7ktQALEojfw/s1600-h/IMG_0644.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghiZYRGHI-ZrD-wScXuLGbre05xPOdxkETCdlP1xAme8hzoKTzONSv_2zByvkuGvAjH9uJbr5JnIR6A4fLLU4pA7cQroc6ZzqnkcsfhRV8NuNm4p4l1paDZ5UkV7F7ty5U7ktQALEojfw/s320/IMG_0644.jpg" width="320" /></a></div><div style="margin-bottom: 0px; margin-left: 0px; margin-right: 0px; margin-top: 0px;"><br />
I considered some options. I could try to turn a jam chuck, remount between centres, and carefully turn the base again. That would give me a good chance at a concentric and nicely flowing base, but given the missing half rim and likelihood of further splitting, the risk seemed too great.<br />
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I thought about evening out the distribution of the chuck marks around the diameter and making decorative features out of them, but really, all I wanted to see was the profile.<br />
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In the end, I hand-shaped the base with chisels and abrasives. The process was tedious, and the result is not concentric or even perfectly circular, but most of the charm of the profile was preserved.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj29TXnvDeeacdHkz_VYi1LCIOsZzCtye_qyvIfXoyhCsjDzZT0ooMesHpHhifXzLiqxz_zGvS4UdUPDTh5HqY5bJN-IAx6bdDa-hIOGvjQvjG4kaZmfkS6-Qd0mYk0lI3kqYPU7vJFIoU/s1600-h/IMG_0649.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj29TXnvDeeacdHkz_VYi1LCIOsZzCtye_qyvIfXoyhCsjDzZT0ooMesHpHhifXzLiqxz_zGvS4UdUPDTh5HqY5bJN-IAx6bdDa-hIOGvjQvjG4kaZmfkS6-Qd0mYk0lI3kqYPU7vJFIoU/s320/IMG_0649.jpg" /></a></div><br />
Instead, I added a pedestal of bike parts. First, I disassembled a very rusty rear wheel from a ladies' cruiser with a coaster brake. I tried the hub as an extension of the profile, but it was too narrow much too soon. I wanted to see the profile flare out again.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs-lcTvqIjP96Mw8XQ03GFZU-G7sG4AsLPHOKpgJ-KWDiucW1QSDFMyoL-moe_ZiKJOqe7n428HMhAhzc90B9E_NRgv7ma02kl3o6HqEFEsbUaXYZPbRfZ42AEZNR6jAAf1DAmrSRgeNM/s1600-h/IMG_0712.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs-lcTvqIjP96Mw8XQ03GFZU-G7sG4AsLPHOKpgJ-KWDiucW1QSDFMyoL-moe_ZiKJOqe7n428HMhAhzc90B9E_NRgv7ma02kl3o6HqEFEsbUaXYZPbRfZ42AEZNR6jAAf1DAmrSRgeNM/s320/IMG_0712.jpg" /></a></div><br />
So I cut three sections of the rim and affixed them around the hub, one end tucked under the flange and against the hub body, and the other splayed out as a foot. To get an idea of the look, I held them in place with elastic bands.<br />
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It looked good, but with three legs the profile depended on the orientation of the pedestal. I didn't like how it looked that way, and so I cut a fourth leg.<br />
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I also used the grinder to cut a recess so that the tops of the legs were outside the flange rim instead of inset. The profile of the bowl flowed into the pedestal better that way.<br />
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<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXTdnT2WEWd1oTIZyBFLL8KCNovazkiYIl_5TQfRIEJgZEoPHIBdDhQIO0rrouRKZeRPotnXTwEwtU-ENujRo7nqBNA3jOVvKEw9tLNuPz4XgErF2wRYQ8GpNDvXYDxRxLTNOzeP-GWPI/s1600-h/IMG_0722.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXTdnT2WEWd1oTIZyBFLL8KCNovazkiYIl_5TQfRIEJgZEoPHIBdDhQIO0rrouRKZeRPotnXTwEwtU-ENujRo7nqBNA3jOVvKEw9tLNuPz4XgErF2wRYQ8GpNDvXYDxRxLTNOzeP-GWPI/s320/IMG_0722.jpg" /></a></div><br />
All welded up, I was very pleased with it. I added an 18-tooth freewheel sprocket at the top of the pedestal, which was just the right size to provide a nice finish for the pedestal top and overhang for shadows.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFGhIOVs9WpjF9X5OyJCDEKBQZ6hXHSkJsv2eUCXc4a2RT_Pjrm2rgKvvjZYpgiRjKrF039RHGLpzHrLi_ZpSSWOz2W0iEFgvrrTIFpMBSNG9Vd-qrl3M2iDuiQmv0bKZiUGkzhW_C7Wk/s1600-h/IMG_0731.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFGhIOVs9WpjF9X5OyJCDEKBQZ6hXHSkJsv2eUCXc4a2RT_Pjrm2rgKvvjZYpgiRjKrF039RHGLpzHrLi_ZpSSWOz2W0iEFgvrrTIFpMBSNG9Vd-qrl3M2iDuiQmv0bKZiUGkzhW_C7Wk/s320/IMG_0731.jpg" /></a></div><br />
I cleaned the pedestal with a toothbrush and alcohol, then hand sanded the bowl to 400 grit and rubbed in a beeswax finish. I avoided oil because I didn't want to further yellow the sapwood or dull the vivid reds and oranges of the branch endgrain.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGZifpFyOQjW3kZiMA1RtRpwxQiXhxlgaB2XgeysCtY4D5aRnx7ZPtW28Zr4TrrZAx9pchwhjtQg_xxLJeZ_Cqnym-xIakRTingmpZ5cAJAG7Wq93YESuz5fTl3gU5rqLihePRPuo8Hi4/s1600-h/IMG_0773.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGZifpFyOQjW3kZiMA1RtRpwxQiXhxlgaB2XgeysCtY4D5aRnx7ZPtW28Zr4TrrZAx9pchwhjtQg_xxLJeZ_Cqnym-xIakRTingmpZ5cAJAG7Wq93YESuz5fTl3gU5rqLihePRPuo8Hi4/s320/IMG_0773.jpg" /></a></div><br />
</div><div style="margin-bottom: 0px; margin-left: 0px; margin-right: 0px; margin-top: 0px;">I love the contrast between the discoloured, rusty, and worn metal, the soft creamy yellow sapwood, and the explosion of reds and oranges. Sometimes persistence pays off.</div>Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-1902408641586792782.post-62160413585566610342010-02-25T12:29:00.000-05:002010-02-25T12:29:03.384-05:00Persistence in the face of turning disastersI resolved to finally finish my nemesis bowl, whether it liked it or not, and so I firmly grabbed it by the base. I planned to figure out a way to deal with the chuck marks later.<br />
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After truing the rim AGAIN, I took my time and peeled away the central column with facing cuts from the bowl gouge. It had been my attempt to take a shortcut by cutting through the column near its base that had caused my massive catch last time, so I just grit my teeth and did it the slow way.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm0un4xDviNszVR5h6t0Q63tCueKGDVHcukiuhlEuprULu5tXNlGblb_gl0qrUpRglRc5UhH7E8r10ImqiME4_yB_MESwznyH-zZW_G1MfJTyYYi7MQBFCMPSH7uM33iGUetL9RJswV3A/s1600-h/IMG_0618.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm0un4xDviNszVR5h6t0Q63tCueKGDVHcukiuhlEuprULu5tXNlGblb_gl0qrUpRglRc5UhH7E8r10ImqiME4_yB_MESwznyH-zZW_G1MfJTyYYi7MQBFCMPSH7uM33iGUetL9RJswV3A/s320/IMG_0618.jpg" width="320" /></a></div><br />
A chunk of loose end grain came flying off while I trued the rim, and it left an interesting shape. As I hollowed, I lost another piece.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqUiiBje6FTMr3kcvdUaimF94CTjJAmqh_naLmzz4TepAnempe-kStGyIWaQRbyaR0vtrSz7Jtfn0R4nq1XIppF3PjpSYcykDzOGKJYKh718q3ksPRVrpB6HlE4XCcU_FN0i6XHeTQZVU/s1600-h/IMG_0624.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqUiiBje6FTMr3kcvdUaimF94CTjJAmqh_naLmzz4TepAnempe-kStGyIWaQRbyaR0vtrSz7Jtfn0R4nq1XIppF3PjpSYcykDzOGKJYKh718q3ksPRVrpB6HlE4XCcU_FN0i6XHeTQZVU/s320/IMG_0624.jpg" width="320" /></a></div><br />
In this photo you can see how I tried to fair the trued rim back into the out-of-true bowl body. It came quite smooth with a little sanding. And you can also see that another chunk came tearing away. I do love my helmet.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH5QHF7-xr9U1SqqilzwYm1qLd2C6Ive5QIAuAUvYoUe4sPiJuwhyphenhyphenYvWe8L0TxeKQxrSjCTnCYR1U2EfTUPP2c1giZnDFy9Y28MiF3GiAOgemkbUWUH5pco8q6EhiABTPDEynEWtq9gH8/s1600-h/IMG_0628.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH5QHF7-xr9U1SqqilzwYm1qLd2C6Ive5QIAuAUvYoUe4sPiJuwhyphenhyphenYvWe8L0TxeKQxrSjCTnCYR1U2EfTUPP2c1giZnDFy9Y28MiF3GiAOgemkbUWUH5pco8q6EhiABTPDEynEWtq9gH8/s320/IMG_0628.jpg" width="320" /></a></div><br />
That's about half the rim gone. I won't be reversing this to finish the foot! Turning half a bowl is interesting, as you can see right through the side of the bowl as it rotates. It's a new perspective on the tool.<br />
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I finished the hollowing and smoothing of the bottom of the bowl with a round scraper, and then resorted to hand sanding to remove the substantial waviness left in the remaining wood. I also used the 120 grit cloth abrasive as a shaping tool to refine the jagged edge left by the breaks.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEip9N2fGeAs0TrvOeNeogQQTXwG0lnMh7EvDgNfdN7cKYly8rgKHZspaBmZIY55Hr1oJ2NMyuHWXrA1iFLIyvggj1JvLtHoBM-5Rk3hrzCEGwjdqLQxy6vGTemUmTErPJ0bQ4pKrtpCK08/s1600-h/IMG_0630.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEip9N2fGeAs0TrvOeNeogQQTXwG0lnMh7EvDgNfdN7cKYly8rgKHZspaBmZIY55Hr1oJ2NMyuHWXrA1iFLIyvggj1JvLtHoBM-5Rk3hrzCEGwjdqLQxy6vGTemUmTErPJ0bQ4pKrtpCK08/s320/IMG_0630.jpg" width="320" /></a></div><br />
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Very interesting, and well balanced by accident. There's more hand sanding to do, but I want to solve the problem of the broken foot next.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-66538335563913248032010-02-24T15:47:00.000-05:002010-02-24T15:47:32.982-05:00Throwing bowls across the shopI had daydreamed about turning bowls from chunks of tree for years before I finally bought a lathe. I made myself learn the basics, of course. But the first time I caught a city maintenance crew felling a big tree in my neighbourhood, I scored a six-foot log. It was a dead or dying Manitoba maple with characteristic streaks of pink and red through the heartwood.<br />
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</div><div>I chainsawed and split it into half rounds and set them aside to dry, but couldn't wait to turn some. I chose an odd crotch piece, wedge-shaped and massive. Any sane turner would have called it firewood, but I didn't know better and thought it would make a fine first green blank.</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfcpnCZI7OVM5iNXeH5n7wBDFLJUzIiZkXzcsknykmZQmn2dMcHp5oqmOj02KM-eeR71szRNw_kCGGo1EW-QS9Vk6yt5kXi04IH20dvZyfO5C_IMTC3JvvTowXQ2xiDq7K0HZckZ-w6XY/s1600-h/img_0324.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfcpnCZI7OVM5iNXeH5n7wBDFLJUzIiZkXzcsknykmZQmn2dMcHp5oqmOj02KM-eeR71szRNw_kCGGo1EW-QS9Vk6yt5kXi04IH20dvZyfO5C_IMTC3JvvTowXQ2xiDq7K0HZckZ-w6XY/s320/img_0324.jpg" width="319" /></a></div><div><br />
</div><div>Look how nice and new that lathe is!<br />
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The chalk marks are where the wood was binding on the lathe bed. I just kept whacking chunks off until it would turn. When the blank was finally free, I switched on the lathe and immediately switched it off, as it was doing its best to walk across the shop from the eccentric weight distribution. (Ever wonder what's in a vibrator? A motor and an eccentric mass, not quite as shown.)</div><div><br />
</div><div>Apparently I got it roughed down somehow, and the blank sat on my shelf for seven years. I had already sawed out a wedge of splintered splits, and you can see the wax on the branch end grain.</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbTsPLT9wH9h2VwY98AchCcAyWBYV-YjWz1EukCpZpklxgrbuM4-rqjx40_AQqgg0uNB9eDRI-UtebcJAtcA-HQaeDM6vuyfqoZxqDBrIDxPfwGMltJ4h1xSMS6R8T5WCXGXHDkucvkFI/s1600-h/IMG_0709.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbTsPLT9wH9h2VwY98AchCcAyWBYV-YjWz1EukCpZpklxgrbuM4-rqjx40_AQqgg0uNB9eDRI-UtebcJAtcA-HQaeDM6vuyfqoZxqDBrIDxPfwGMltJ4h1xSMS6R8T5WCXGXHDkucvkFI/s320/IMG_0709.jpg" width="320" /></a></div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtp9-fDhLYmQ9D652xM6JH-avNokbOOcqhQ5pVFlSulN_nRq0BjaBu2GZwGB8TsVGeYhzoj9lzmDu50TsDWgQZCjR28kQ51ORvk5HUu2ZRaS_UKSSH-b93lbouvTk_V4GGkSTn66KkGYA/s1600-h/IMG_0711.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtp9-fDhLYmQ9D652xM6JH-avNokbOOcqhQ5pVFlSulN_nRq0BjaBu2GZwGB8TsVGeYhzoj9lzmDu50TsDWgQZCjR28kQ51ORvk5HUu2ZRaS_UKSSH-b93lbouvTk_V4GGkSTn66KkGYA/s320/IMG_0711.jpg" width="320" /></a></div><div><br />
</div><div>I had tried finish turning it once already, and had more or less trued it up and begun flattening the rim when I had a catch that sent the bowl flying off the screw chuck and across the workshop. Enough time had passed that I was ready to try again.</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFGDUGeDplWBBP03jOF1Z5jpkfaT6qRVfhzmRxpSN5xTLRGlTTf1i_BAOmpWl4l8deLKeVQ68smyc0vJUug4hv9dLVF1GXSukUD6SnspOVxnRK9lmns1hn0_ea5EMQEf8CE4hbPhyEkcY/s1600-h/IMG_0713.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFGDUGeDplWBBP03jOF1Z5jpkfaT6qRVfhzmRxpSN5xTLRGlTTf1i_BAOmpWl4l8deLKeVQ68smyc0vJUug4hv9dLVF1GXSukUD6SnspOVxnRK9lmns1hn0_ea5EMQEf8CE4hbPhyEkcY/s320/IMG_0713.jpg" width="320" /></a></div><div><br />
</div><div>I grabbed it by the foot, used the tailstock to adjust it to run as true as I could, and then turned a tenon for the chuck into the central column I had left while rough hollowing.</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFYIkdtfHjU3hOv6QIbOD6CLaJi-i7CyfCd6SiCHfnDrnQmHDjcllSB-sHdq2JnzkZ3eDpbu-uKamEx_NTHUWoIJlZBotNYJKSkzLJ61d7_5krjnbAP5GB1NJyqS5PS88KSfRHTHIs4WE/s1600-h/IMG_0714.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFYIkdtfHjU3hOv6QIbOD6CLaJi-i7CyfCd6SiCHfnDrnQmHDjcllSB-sHdq2JnzkZ3eDpbu-uKamEx_NTHUWoIJlZBotNYJKSkzLJ61d7_5krjnbAP5GB1NJyqS5PS88KSfRHTHIs4WE/s320/IMG_0714.jpg" width="320" /></a></div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_ZZygXS_a4ZBxDkXw9ouQluqf7TSuHzwlUQ0r_kTkX0ta7CnyjC5znmpJ_ysy2S-NAbgC0ghUD0OAii6K5vZCNefS58ZwH8weMHIYJl7sPd0L79e3xpuj-IxoJerabLAz00d-XWZuHdw/s1600-h/IMG_0715.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_ZZygXS_a4ZBxDkXw9ouQluqf7TSuHzwlUQ0r_kTkX0ta7CnyjC5znmpJ_ysy2S-NAbgC0ghUD0OAii6K5vZCNefS58ZwH8weMHIYJl7sPd0L79e3xpuj-IxoJerabLAz00d-XWZuHdw/s320/IMG_0715.jpg" width="320" /></a></div><div><br />
</div><div>Reversed and grabbed by the tenon, I could true the figure on the new centre. After some sanding it started to look pretty good.<br />
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Time to cut a new foot. My chuck manual says that the minimum recess diameter for an inside grip is 2 3/8 inches, so I dutifully used that dimension. I was justifiably worried about the skimpiness of the foot, but foolishly ignored my misgivings.</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE7eJV62Zo6VdQvnpyMdIKmL0uNM5jXS5RiIiy4lE5IKNdz7p8EoN0rLfbdgtc4mi4Syj0WjIy3seqdryGUdYjgqlJT3N6rDOnHn8pCzSslLArShoArjniMyAZILb2o8NDqOLuyanCA1M/s1600-h/IMG_0604.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE7eJV62Zo6VdQvnpyMdIKmL0uNM5jXS5RiIiy4lE5IKNdz7p8EoN0rLfbdgtc4mi4Syj0WjIy3seqdryGUdYjgqlJT3N6rDOnHn8pCzSslLArShoArjniMyAZILb2o8NDqOLuyanCA1M/s320/IMG_0604.jpg" width="320" /></a></div><div><br />
In truth, it looks like the chuck will grab a much smaller inside diameter, maybe as little as 2 inches, and I will ignore the manual and use the smallest recess that works in future. But in this case, I went for it, had a catch in the hollowing, and sent the bowl flying across the shop again, with a chunk of the foot missing. My fault, of course. I set it aside until I am not angry with it again.</div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-83084737450210386582010-02-23T12:43:00.000-05:002010-02-23T12:43:01.590-05:00Finishing Bikes and Trees 2With the turning complete, I had to figure out how to get a clean, straight slice through the work on the bandsaw. First, I made a sacrificial V-sled the hard way by grabbing a nasty old cedar table leg out of the burn pile, jointing and squaring it, and then taking angled cuts out on the tablesaw. Completed, it cradled the turning securely and let me use the mitre gauge to set the cut angle.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDT9x17Ubg7WqUubVhjU14Vax2Ov5_DI5cQ4mVqxJWQIRQqOZitp5_LovIG6r_gmYMN9UxEdKv3H6zgX6rvsi_xRtBtIzZzfYn11hYKd9RCm-ivhpVG8PlL7pkvRJ_wqWWYyJOb8sBT8Y/s1600-h/IMG_0414.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDT9x17Ubg7WqUubVhjU14Vax2Ov5_DI5cQ4mVqxJWQIRQqOZitp5_LovIG6r_gmYMN9UxEdKv3H6zgX6rvsi_xRtBtIzZzfYn11hYKd9RCm-ivhpVG8PlL7pkvRJ_wqWWYyJOb8sBT8Y/s320/IMG_0414.jpg" width="320" /></a></div><br />
I also took the time to carefully reset the blade tension and guides so that the blade stayed quite straight and did not wander. I was rewarded with a very clean cut. I can't see any blade tracks in the photo, and it sanded dead flat in just a few strokes. (To keep flats while sanding, I lay a full sheet of sandpaper on a flat table, lay the flat of the work on it, figure out how to hold the work to avoid any rocking, and then take straight light strokes back and forth. It usually works out very well.)<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb56jMcIMIJEtLWzMr-7WZPzFqqF9qwu_ujHgN49zKjqu0EKfatTc41WZ3NegUNx6SyAwvppJanUhA9W0n3Dj9c2Gnzx0MkB3U0GV9ap0kCqWBcw81ExKOzpnPBKcrg8yC-1Ka0SxrXdU/s1600-h/IMG_0418.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb56jMcIMIJEtLWzMr-7WZPzFqqF9qwu_ujHgN49zKjqu0EKfatTc41WZ3NegUNx6SyAwvppJanUhA9W0n3Dj9c2Gnzx0MkB3U0GV9ap0kCqWBcw81ExKOzpnPBKcrg8yC-1Ka0SxrXdU/s320/IMG_0418.jpg" width="320" /></a></div><br />
A quick test fit kept me excited about the project. I like this:<br />
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But the sphere was now clearly oval, as the kerf of the cut was much thinner than the sprocket. I measured the difference with calipers and marked the excess with a round marking gauge.<br />
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<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSGOT8j-ekGKcbSRtrxs2-jFB6gB87RKXR_1di10I1oq-aEGtBbexPG-IwPHF2trD8V8PXPkXnqN6ntLKEzm61HLbTzGKeCmgJBehMuzFoUhK6IcFKvTBxWbjidvwt5_-NscbX1CaCEco/s1600-h/IMG_0439.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSGOT8j-ekGKcbSRtrxs2-jFB6gB87RKXR_1di10I1oq-aEGtBbexPG-IwPHF2trD8V8PXPkXnqN6ntLKEzm61HLbTzGKeCmgJBehMuzFoUhK6IcFKvTBxWbjidvwt5_-NscbX1CaCEco/s320/IMG_0439.jpg" width="320" /></a></div><br />
Doesn't that look precise and sophisticated? I think the Fine Woodworking magazine next step would be to construct a shooting jig for a low-angle bench plane and take sweet shavings of end grain off until the marked line was just kissed. But I'm not that good.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgC7Xt95GIYxqQnTFFXj3VEooHLjfcimv3haZTkQ6tZMIyPREM5FuC9MQA4gEEHd7hwNdHYQvo6-LywWGhAjMU9KxIJTHlldnYYz9e2smfxSnqlmz3nO779FJ5NeSLbcQ76lZAe3uf1-7o/s1600-h/IMG_0453.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgC7Xt95GIYxqQnTFFXj3VEooHLjfcimv3haZTkQ6tZMIyPREM5FuC9MQA4gEEHd7hwNdHYQvo6-LywWGhAjMU9KxIJTHlldnYYz9e2smfxSnqlmz3nO779FJ5NeSLbcQ76lZAe3uf1-7o/s320/IMG_0453.jpg" width="320" /></a></div><br />
Instead, I clamped a belt sander upside down on the bench and did my best to sand down to the line more or less flat. More less, in fact, which led to a lot more hand-sanding to restore the flat. (So maybe the shooting jig is the right thing, really.) But it got there.<br />
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I carefully put the sprocket right where I wanted it, and then traced the inside onto the wood. I had started out with the idea of a loose tenon, and then dowels, but drilling into the top was looking like trouble. I decided to use brads as pins, which let me progressively refine the orientation of the gear by adding brads.<br />
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Once the sprocket was locked in place, I snipped the heads off the brads and carefully positioned the top. Once I was certain it was where it needed to be, I pressed down to mark the pin locations, and then drilled at the marks. With a tiny drill bit, I could just hold the top to prevent it tipping on its round.<br />
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The press fit was very firm, and so I completed the assembly without glue after finally hand-sanding the turning with the grain. With a rubbed coat of walnut oil, it turned out very nearly as I had hoped:<br />
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I don't think that this will be the last of this sort of thing, as my head is exploding with variations on this theme. It's fun to be inspired!Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-1902408641586792782.post-49810326379600172102010-02-22T11:15:00.000-05:002010-02-22T11:15:37.171-05:00Turning Bikes and Trees 2Two of my lifetime passions are cycling and woodworking, bicycles and wood. I am inspired to look for interesting ways to integrate them. Here, for example, is a slightly rusty freewheel sprocket and a nice quarter section of black walnut.<br />
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My intention was to turn a sphere and bisect it with the sprocket.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCjCwE8PBtw6BXSqAf1GTa2hvHwBpLu5oByTPChRtSRmcRuelBOWQqtefz03KEgJPUfjK-nVB4BWfpRQJvdT4-SeGdigyI9vgxlN4Cux3vmaGgPIsBq50Zt85FtLwa75NYNEBhDZl7FFk/s1600-h/IMG_0379.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCjCwE8PBtw6BXSqAf1GTa2hvHwBpLu5oByTPChRtSRmcRuelBOWQqtefz03KEgJPUfjK-nVB4BWfpRQJvdT4-SeGdigyI9vgxlN4Cux3vmaGgPIsBq50Zt85FtLwa75NYNEBhDZl7FFk/s320/IMG_0379.jpg" /></a></div><br />
The first thing to do is rough the wood down. I marked and punched the centreline I wanted at each end of the log, then bandsawed away a big chunk of waste and mounted the blank on the lathe. That's the roughing gouge sitting on the wood. It chips and peels the wood away very quickly, and doesn't rely on the work already running true for a good cut. You can just pass back and forth, sending chips flying. Eventually you will have a cylinder.<br />
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I wanted to start with a diameter similar to the gulleys of the sprocket's teeth, so I set a pair of calipers to that dimension. The parting tool is lying across the calipers, as I planned to use it to establish the diameter.<br />
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I laid out the sphere with three pencil rings, intending to leave the centre one and turn down to the outside marks. Partway there, I noticed a large split developing at the tailstock end. I stopped, flooded the crack with cyanoacrylate glue, and tightened a hose clamp around the end. (I removed the hose clamp before resuming turning! It's just posed on the lathe like this.)<br />
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I had time to think, and decided that I had better make myself a half-circle template if I was to have any hope of achieving a sphere. As it turns out, the diameter I'm eventually looking for is about 2.5 inches, and I have a hole saw in that size. I made a quick plywood template and used an orange pencil crayon to mark the highest spots.<br />
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Mark, turn away marks, mark, turn away marks... it didn't take long to get quite close to spherical. By this time my vision had changed and I wanted to leave the sphere on a simple footed post, and then set the sprocket at an angle.<br />
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I had used a square scraper to peel down the post, and now switched to using it instead of the gouge on the sphere as I crept up on the shape.<br />
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I sanded to 240 grit on the lathe and then parted the base off. I made a hash of the parting off, and the bottom of the base was indeed undercut but also badly scored. I mounted a sanding disc in a Jacob's chuck and cleaned up the base, doing penance for my turning error.<br />
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Now I had to figure out how to slice through the sphere in a straight line at the right angle. I didn't want to use the tablesaw, because I don't have a thin-kerf blade and don't want the sphere to become squashed. So I decided that meant a jig on the bandsaw and sanding to fit.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-53886297365928263712010-02-19T06:35:00.000-05:002010-02-19T06:35:31.232-05:00Welding a scrap steel cowbellBefore I finished folding the cowbell closed, I took a hand file to the edge of the back that will be welded to the bottom. I wanted it to lie nice and flat. I also put a slight bevel on the corners so that they wouldn't bind during final bending.<br />
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I haven't found a way to effectively clamp the bend while closing the cowbell, so I laid the top of the cowbell flat on my jointer table and tried to push the bend over further with a length of angle. I persuaded the joint into position with clamps, then locked it down with a big welder's C clamp. (G cramp, UK. Wotcher!)<br />
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My welding is improving. The major mistakes I made this time were in positioning the work and retouching the weld. I laid the cowbell on its side with the weld up, and the heat caused the sheet steel to sag noticeably. It would probably be better to position the cowbell on its mouth so that the side is supported while welding. The excessive retouching didn't help because of the heat buildup.<br />
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However, I did get a complete, solid, gap-free weld all the way around on the first try this time, which pleased me. Strong first, pretty later, I guess.<br />
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The next step is to drill out the mounting bracket. I put a 3/8 twist drill in the drill press and laid the cowbell on its top face (which is coplanar with the top of the mounting bracket, unlike the bottom). I eyeballed centre, put a bead of cutting oil in place, and slowly went straight through the bottom and then the top of the bracket, ensuring perfect hole alignment. Then I swung the table out of the way, stood the cowbell on its mouth on some blocks, and drilled a similar hole in the back for the thumbscrew.<br />
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I used 5/16 18 TPI rod and nuts for this cowbell, but as long as your hardware is sturdy and all fits together it doesn't much matter. To receive the screw, I welded a flanged nut onto the inside of the back of the bracket. A short bolt and second nut keeps the flanged nut in place.<br />
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I managed to grab the camera in time to catch the glow. It fades fast in the Canadian winter!<br />
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Finally, I wire-brushed the cowbell on all sides to remove the enamel and welding grunge. I like the brushed finish.<br />
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My local hardware store doesn't have thumb screws, so I used threaded rod and a wing nut. I have noticed that the world looks different now that I think of metal as something I can modify like wood.<br />
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I welded the wing nut on to the end of the rod, trimmed the rod to length with a cutoff wheel, and beveled the end on the grinder.<br />
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As a bonus, it looks way cooler than bright plated hardware store stuff.<br />
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This cowbell lacks the two distinct notes of the first one, which was 6 inches long and made of 23 gauge steel. At 5 inches and 20 gauge, it has a single ringing note that is higher than the last one, but still pitched lower than my storebought cowbell. Here's audio:<br />
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<div style="text-align: center;"><object classid="clsid:d27cdb6e-ae6d-11cf-96b8-444553540000" codebase="http://fpdownload.macromedia.com/pub/shockwave/cabs/flash/swflash.cab#version=8,0,0,0" height="28" id="divplaylist" width="335"><param name="movie" value="http://www.divshare.com/flash/playlist?myId=10487502-93f" /><embed src="http://www.divshare.com/flash/playlist?myId=10487502-93f" width="335" height="28" name="divplaylist" type="application/x-shockwave-flash" pluginspage="http://www.macromedia.com/go/getflashplayer"></embed></object></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-68363154547032208202010-02-18T12:08:00.000-05:002010-02-18T12:08:50.992-05:00Folding a scrap steel cowbellSomeday I may feel justified in buying myself a sheet metal box bending brake so that I can do this right. In the meantime, I worked around the missing tool by making a brake jig for each bend with a couple of lengths of slotted angle. I clamped a length of angle along the bend line, front and back, and used the benchtop or another length of angle to push the steel over. The angle spreads the force and prevents the metal from folding, bending, or creasing anywhere other than intended.<br />
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I find that to get the fold right on the line, I need to place the outside angle edge right in the middle of the line, and the inside edge just under it. That is, the inside angle is set perhaps 1/32 inch below the outer one, to account for the thickness of the material and the radius of the bend.<br />
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The sequence of bends is also important. I folded the back over first, and then made the long folds, starting at the over flap and finishing with the under flap. It would be very difficult to fold the back last.<br />
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I had to persuade a couple of the long bends to square up a bit with an anvil and ball peen hammer.<br />
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The last bend can only go to about 45 degrees before it binds on the guide angles. That's OK, because I still need to brush off all of the enamel in the general area of the welds.<br />
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The mounting bracket will be folded over after the cowbell is welded closed.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-68387077744168803592010-02-17T12:15:00.000-05:002010-02-17T12:15:58.773-05:00Cutting a scrap steel cowbell<div class="separator" style="clear: both; text-align: center;"></div>I have been cutting sheet steel with the oxy-acetylene torch so far. It's fun and exciting, but I get very poor results. For this cowbell, I tried a cutting wheel in the angle grinder and used a length of slotted angle as a guide and fence.<br />
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The results were encouraging. I took a photo of each step in the process:<br />
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At this point I had gotten a bit zoned into the through cuts, and I needed to avoid messing up on the remaining stopped cuts, so I put a bit of red tape at the stop point.<br />
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That last little triangle of material between the back and mounting bracket can't be reached by the cutting disc. I clamped a length of slotted angle along both sides of the cut line, snapped a vise grip plier onto the waste, and wiggled it back and forth until metal fatigue set in and it separated near the line.<br />
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Nice and neat, minimal post-cutting cleanup required, and I've saved myself a lot of grinding with this refinement. I did flip the workpiece over and grind away all of the cutting burrs.<br />
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Then I wire-brushed the inside clean of all enamel and grunge, for weld preparation and finished appearance.<br />
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Ready to fold!Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-41222530364630290552010-02-16T11:01:00.001-05:002010-02-18T21:03:31.382-05:00Laying out a cowbell, step by stepIn my last post on making a cowbell from the side panel of an abandoned dishwasher, I didn't provide details of how to lay out the pattern. For that one, I used trig to figure the angle of the large trapezoids, then used my tablesaw mitre gauge to set that angle, and a bevel gauge to transfer it. Ridiculous.<br />
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This cowbell will be similar to the last, but where it was 6 inches long, this one will be 5 inches. The other dimensions will be the same: 3 x 1 1/2 at the mouth, and 2 x 1 at the back. The finished pattern looks like this:<br />
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<div class="separator" style="clear: both; text-align: center;"><span class="Apple-style-span" style="font-family: inherit;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihoadw7-ldF_m0YvfaJrYBPpwN6aH9LiL64fFixjsZQ5dLGOXNwdMAMy9TK9B0RKEbd4SVJAQJvrSC6RIZlFd2P4YVg7OxIIW42uGPslW8MbaPFzJoqrcExq7NhyphenhyphenVVDy9c8IOz_t_gp1U/s1600-h/IMG_9954.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"></a></span></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4QnwyAgQrtlyT03mmlCj4gxPYksYJKg6K0fBLs4jSsoZdnyhabUawN9DGFCBNxk2Xv6swgZTWdMbIjRUebxg_BNRXkpOWzDvas8991kpiV80Rn_FDIOEdN-cGqNGttEmsg3wZZHKzxqc/s1600-h/IMG_0121.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4QnwyAgQrtlyT03mmlCj4gxPYksYJKg6K0fBLs4jSsoZdnyhabUawN9DGFCBNxk2Xv6swgZTWdMbIjRUebxg_BNRXkpOWzDvas8991kpiV80Rn_FDIOEdN-cGqNGttEmsg3wZZHKzxqc/s320/IMG_0121.jpg" /></span></a></div></div><br />
I labeled the top, bottom, and over and under flaps of the welded side. The unlabeled side in the centre is where the layout starts.<br />
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I found <a href="http://www.motherearthnews.com/Do-It-Yourself/1984-09-01/Copper-Cowbells.aspx" target="_blank">this article</a>, which suggests using a cardboard pattern. And once I started thinking about that, I agreed that the whole thing can be drawn more easily, accurately, and repeatedly without any trig or angle transfers. I used an empty cereal box for my patterns. <br />
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To draw the large trapezoid, I first marked the endpoints of a line that is 5 inches long. I labeled them as C and C'.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV78i41ODnwvrqKdxVEZ2JGwhiJlrYdiCRpU1nA5Qu5PmN8bakTBr58sCtsnUYM5ivGxqF-XppBd0qr_yzOZiQXDuG7L-wkHwkKTs11KLaocmfqabsI5O7gM7JWpq1iQuoYDFrMv0zZlA/s1600-h/IMG_0081.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV78i41ODnwvrqKdxVEZ2JGwhiJlrYdiCRpU1nA5Qu5PmN8bakTBr58sCtsnUYM5ivGxqF-XppBd0qr_yzOZiQXDuG7L-wkHwkKTs11KLaocmfqabsI5O7gM7JWpq1iQuoYDFrMv0zZlA/s320/IMG_0081.jpg" /></span></a></div><br />
That line is the centreline of the trapezoid. The mouth is 3 inches wide, so I marked dots at 1.5 inches either side of C, square to the centreline. It's two inches at the back, so I marked 1 inch on each side, and then drew the lines.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7rAOl3oQJCqv_dKfa511b6sBkThGsXZbPXqgd5fHFlMIF5ZOUq8NNiqpbYNgXi2gOqSssf2P11hKqIBlJdC7hHB2l3rZX1RsJTJenv4_4Tx6npbv9AABtnvcOkJrcAr3H7S5AFk-3ZT8/s1600-h/IMG_0083.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7rAOl3oQJCqv_dKfa511b6sBkThGsXZbPXqgd5fHFlMIF5ZOUq8NNiqpbYNgXi2gOqSssf2P11hKqIBlJdC7hHB2l3rZX1RsJTJenv4_4Tx6npbv9AABtnvcOkJrcAr3H7S5AFk-3ZT8/s320/IMG_0083.jpg" /></span></a></div><br />
I plan to make more of these in different sizes, so I made patterns for 5, 6, and 7 inch cowbells with the same mouth dimensions. (Of course I'll experiment with the mouth dimensions at some point too.)<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJP6o0hgN3SML1pA18I164on73eapl8yK4COrA2PXs-8cv2tc6U9LJuojOI-YPIq4Ndeifug5ZrSXgvgTklldka6YbouRa4bkioOpJaWE0Q42gqaCbtuQwiyFtjPmNhVwDxuQxmrpPP9I/s1600-h/IMG_0090.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJP6o0hgN3SML1pA18I164on73eapl8yK4COrA2PXs-8cv2tc6U9LJuojOI-YPIq4Ndeifug5ZrSXgvgTklldka6YbouRa4bkioOpJaWE0Q42gqaCbtuQwiyFtjPmNhVwDxuQxmrpPP9I/s320/IMG_0090.jpg" /></span></a></div><br />
I didn't make a simple rectangle pattern for the back and mounting bracket, but I should have and will next time. In this case, it would be 1 inch by 2 inches.<br />
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To draw the cowbell pattern on some scrap sheet steel, I inset the small trapezoid cutout from the edge of the panel and marked its four corners.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg10tDS2nJdQ5CvRxO1cykjdUWQwOGJxA4m4FSsMZJDI_qFRpmK1UPstJ-K6XnX51ROUKi2DzvlT3OVpUie_qxuy4t-D7D8CvsrwIgTfLfHYplXGSR1nt77jCO93ioMNVqg1UE5kdAB5SE/s1600-h/IMG_0094.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg10tDS2nJdQ5CvRxO1cykjdUWQwOGJxA4m4FSsMZJDI_qFRpmK1UPstJ-K6XnX51ROUKi2DzvlT3OVpUie_qxuy4t-D7D8CvsrwIgTfLfHYplXGSR1nt77jCO93ioMNVqg1UE5kdAB5SE/s320/IMG_0094.jpg" /></span></a></div><br />
Then I aligned the left edge of the large trapezoid with the dots at the right edge and marked its other two points. This will be the bottom of the cowbell.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTvuBEmveG6G40DjhFs1g8hbCGQtk-QDovyg2m18chKtQwaUqweHy3CjROnjGXC42oviViiI3kiggv0soODnjoSlsIAB_rY4T5p_NRiQ_tTMesdSOGPcthV-kmrGVhqKYqwRGHxJC3kT0/s1600-h/IMG_0097.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTvuBEmveG6G40DjhFs1g8hbCGQtk-QDovyg2m18chKtQwaUqweHy3CjROnjGXC42oviViiI3kiggv0soODnjoSlsIAB_rY4T5p_NRiQ_tTMesdSOGPcthV-kmrGVhqKYqwRGHxJC3kT0/s320/IMG_0097.jpg" /></span></a></div><br />
I used the small trapezoid aligned with those marks to mark the under flap.<br />
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The top and over flap were laid out in the same way on the left side of the pattern.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhe8ZOGcjdeJKOGQP6XcotGObLYIosnk0ZBCFnL-wv8TvteQXvihx4TP7g_8Kk5BbaUniMNgUkaHdMWemhyphenhyphend9LdUA3QxH8K93gduuaEm2J4bOQFgm1tp7DjyOcLddvjb0PQZAKUfc1SWIU/s1600-h/IMG_0109.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhe8ZOGcjdeJKOGQP6XcotGObLYIosnk0ZBCFnL-wv8TvteQXvihx4TP7g_8Kk5BbaUniMNgUkaHdMWemhyphenhyphend9LdUA3QxH8K93gduuaEm2J4bOQFgm1tp7DjyOcLddvjb0PQZAKUfc1SWIU/s320/IMG_0109.jpg" /></span></a></div><br />
I dotted the fold lines and stroked the cut lines. As usual, I stroked where I should have dotted and hashed the line to compensate.<br />
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Add a rectangle to the bottom, which will fold to become the back, and three to the top for the mounting bracket. Like this:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguG1YBBVeEVuRRfJSduqslr5nWQCQf2IiDQpw48vgyr3mThqBqL65PBISVfKtsBScsqfflRVnLc3iygdT0F6FBIlOkhEMsIvVf7umZhR7QQIfifDPGfItkJ4qpA9SnMc1wTP-7qUFmQYY/s1600-h/IMG_0121.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguG1YBBVeEVuRRfJSduqslr5nWQCQf2IiDQpw48vgyr3mThqBqL65PBISVfKtsBScsqfflRVnLc3iygdT0F6FBIlOkhEMsIvVf7umZhR7QQIfifDPGfItkJ4qpA9SnMc1wTP-7qUFmQYY/s320/IMG_0121.jpg" /></span></a></div><br />
I want to try cutting this one out with a cutting wheel in the angle grinder. I've marked my intended cuts in the photo below. I'll post later about how it turned out!<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihrvMoJiB_ZmyE_14lwTXnL2Wl7itH2kMfveaYrpNez3pXCj_Yk1p83i5f7-SDOoJJUGUl1xuXa4bctJESA5oobJ8ZUuUdKwDhgiW_1O6POB9TrXJM_-wxnoU4uwanUYFSm-L9JyU40HQ/s1600-h/IMG_0122.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span class="Apple-style-span" style="font-family: inherit;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihrvMoJiB_ZmyE_14lwTXnL2Wl7itH2kMfveaYrpNez3pXCj_Yk1p83i5f7-SDOoJJUGUl1xuXa4bctJESA5oobJ8ZUuUdKwDhgiW_1O6POB9TrXJM_-wxnoU4uwanUYFSm-L9JyU40HQ/s320/IMG_0122.jpg" /></span></a></div>Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-88569864017828625702010-02-15T05:41:00.000-05:002010-02-15T05:41:48.239-05:00Rescuing a rough turning mistakeAfter I got a lathe, whenever I heard the city tree maintenance people fire up their chainsaws I wandered over to find out what they were trimming. I usually ended up with a hunk or two of timber worth keeping. I got into the habit of setting up bowl blanks by halving and waxing the end grain of rounds of green wood, and I now have a shelf full of the stuff. Once in a while, I grab one, bandsaw or chainsaw it more or less round, and rough turn it. The idea is that since the wood is going to move when you hollow it, you go ahead and let it, leaving enough material that you can then turn it round again later.<br />
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This maple blank was rough turned in Jun 2004, according to the pencil scrawl.<br />
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Sometimes, though, I get carried away with the hollowing and don't leave myself anything to hold onto to rechuck the bowl. I gripped the foot in the chuck, trued the edge, and then cut a recess for the chuck jaws. But when I tried to turn it around so I could shape the outside and foot, I found that the jaws could not reach the recess.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4RoSRYVGCdtVrqJ2DGgzmkMt8ZeVyzhr3WtwdtBl0SelRATdBX_DLQx0hw-Y2eD_vtpHwvHMnxX9dYP3VOE0U4aZUrva4UqR4xsK8yj77JajZtmUTwKtV9tF6Q10Z9RoS5UM6DtNrbcc/s1600-h/IMG_8871.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4RoSRYVGCdtVrqJ2DGgzmkMt8ZeVyzhr3WtwdtBl0SelRATdBX_DLQx0hw-Y2eD_vtpHwvHMnxX9dYP3VOE0U4aZUrva4UqR4xsK8yj77JajZtmUTwKtV9tF6Q10Z9RoS5UM6DtNrbcc/s320/IMG_8871.jpg" /></a></div><br />
I left it sitting like that for a week or so, until it stopped annoying me. Then I realized that if I glued it to a panel, I could just thread it onto a screw. So I roughed out a panel of leftover nasty plywood and mounted it on the lathe.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXGTDnFu38_5fpfG25XOkwE05xqVPSi2R9D9m8Ymh_b_zoHPaf3_9uOH4SCHE5dO_hwsd_CSlAu4V9eFi1oWDOT2F2w2xSHIg4ceio2Q6mChDjJerRPPoYNrBU0Q3O1oTVQaAyT2JDa6w/s1600-h/IMG_8873.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXGTDnFu38_5fpfG25XOkwE05xqVPSi2R9D9m8Ymh_b_zoHPaf3_9uOH4SCHE5dO_hwsd_CSlAu4V9eFi1oWDOT2F2w2xSHIg4ceio2Q6mChDjJerRPPoYNrBU0Q3O1oTVQaAyT2JDa6w/s320/IMG_8873.jpg" /></a></div><br />
A good generous bead of glue on the bowl rim...<br />
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...and clamped with the tailstock.<br />
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It worked perfectly! I was able to complete the bowl and just turn the plywood away when it was no longer needed. I'm sure I've got other blanks with this problem, so I'm glad I figured it out.<br />
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This bowl became my Dad's Christmas present, as may be obvious from the photo. That's a bicycle chainring trapped in the wood, and the maple was coloured with many stain coats of old coffee.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgLaK-04nBogIfi_uT94lcpR86AeXZcvEVpQJS4uwu33gKKgwzwxixeoOG_XM5HBavZRtdbWyNGGE1FdbwKUZObZ-TztMcraKOwBwY5_u4ICSpc3jFUoyJksUyai9gU8iE_4TUtA5vONk/s1600-h/IMG_9459.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgLaK-04nBogIfi_uT94lcpR86AeXZcvEVpQJS4uwu33gKKgwzwxixeoOG_XM5HBavZRtdbWyNGGE1FdbwKUZObZ-TztMcraKOwBwY5_u4ICSpc3jFUoyJksUyai9gU8iE_4TUtA5vONk/s320/IMG_9459.jpg" /></a></div>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-16619112514506895682010-02-13T06:31:00.000-05:002010-02-13T06:31:26.327-05:00Preparing blanks for banglesMy bangle stock was running low, so I rummaged through the burn pile for some offcuts and leftovers. I came up with a half round of black walnut, some 8/4 maple and cherry, and some boards of maple and poplar. (In the photo: top and left, black walnut with bark; upper left and lower right, maple; the small red chunk is cherry, and the long board under the cherry, maple, and walnut is poplar.)<br />
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I've posted previously about how I make these. To make it easy to remove the bore with a hole saw after turning, I establish the groove from both sides. The centre hole will be reamed out to 3/8" for the lathe screw chuck, and trying to use a hole saw with an oversize guide hole is dangerous and disastrous for workpieces. The groove ensures that the saw doesn't wander later.<br />
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After the bores are established, I cut the blanks free with a larger hole saw. Sometimes I cut flats on the tablesaw instead, for polygonal or faceted bangles.<br />
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Once a blank is screwed onto the lathe, I use a bowl gouge to true and shape the bangle. I turn one side of the bracelet, then turn the blank around and shape the other side before sanding to remove the gouge marks. The hole saw leaves a coarse finish on the inside of the bore, so I use a sanding drum to smooth and polish it before final hand-sanding and finishing.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcHtLEt0ZmzUTQDbu6Ynv1anAXOzbUJzcpP-5Z5jsnPKK77lzZIak32gXjTaNGM7soAb29Db54pZ8-Rb5C6U8Q3ATiSUVEs1gTgf1ldiTaNDFOt9rZlRdYPJASRB_dXEtBFdDEVXF_hGc/s1600-h/IMG_0067.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcHtLEt0ZmzUTQDbu6Ynv1anAXOzbUJzcpP-5Z5jsnPKK77lzZIak32gXjTaNGM7soAb29Db54pZ8-Rb5C6U8Q3ATiSUVEs1gTgf1ldiTaNDFOt9rZlRdYPJASRB_dXEtBFdDEVXF_hGc/s320/IMG_0067.jpg" /></a></div><br />
Walnut rarely disappoints with its figure, but often it's the offcuts and reject pieces that show the most dramatic grain. Voids, bark inclusions, splits and knots all look great finished but are usually avoided for most work. I really like redeeming these unwanted scraps.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1902408641586792782.post-27981199153402830012010-01-23T13:45:00.001-05:002010-02-15T07:39:23.512-05:00Making a cowbell from scrap steelIn a previous post, I wrote about disassembling an old dishwasher for parts. I've been cutting cowbells out of one of the steel side panels, and on my third attempt, I made a pretty good one. Here's how.<br />
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I tried a couple of patterns, some in multiple pieces, but wasn't happy with the results. I wanted a single seam down one side of the bell, and I wanted the mounting bracket to be integral. This is the layout I developed for this cowbell.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs4EVDNGXDUKQ6tEfFC8gCPjZyASHKfdARgka-DSfkaZ5spgYwZsXr9SpC7i4DP9CfoS-lThkbQcz-PJDNcknLUYx-u0tsBaM99k-E7Fv3yE0CX75-qURyMP2ciqAqjsmTXF5OOI21prU/s1600-h/IMG_9507.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs4EVDNGXDUKQ6tEfFC8gCPjZyASHKfdARgka-DSfkaZ5spgYwZsXr9SpC7i4DP9CfoS-lThkbQcz-PJDNcknLUYx-u0tsBaM99k-E7Fv3yE0CX75-qURyMP2ciqAqjsmTXF5OOI21prU/s320/IMG_9507.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwRUVX7LSOAAaWdf8phPLwZG872KYx1ec8GmFCt_d0YGkkQlzoTPKqZy0ZSf8-XHtAWGAnFJ8q2iZDU-5SKPYzZ-GFIECWpSllfSWQsIAIhbWA7xdmUqUaKOKgBWRNlNfQjJxqEx4_Sh0/s1600-h/IMG_9508.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwRUVX7LSOAAaWdf8phPLwZG872KYx1ec8GmFCt_d0YGkkQlzoTPKqZy0ZSf8-XHtAWGAnFJ8q2iZDU-5SKPYzZ-GFIECWpSllfSWQsIAIhbWA7xdmUqUaKOKgBWRNlNfQjJxqEx4_Sh0/s320/IMG_9508.jpg" /></a></div><br />
The tricky part is getting the angles of the trapezoids <span style="text-decoration: line-through;">right</span> correct. I'll post later about my approach, which worked well and was minimally annoying.<br />
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The dots are folds, and the solid lines are cuts. The solid lines with hashes are where I forgot and marked a fold as a cut. It's important to be clear, because with the welder's shield on and the torch throwing sparks, it's easy to get confused.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6y_JNzFx6Vqfw8akNI7n6Fxpz5AdsXrTJgUnsc9VdWVl8s6pNfcE4pgTh7XS8H5Sr-0E0jZn9VQliVKuYGEuQqUKLxUgROs90MrDK9FdKUOjaG95XIGwYwtxehyrH6MQAcTiPQUu-aAs/s1600-h/IMG_9512.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6y_JNzFx6Vqfw8akNI7n6Fxpz5AdsXrTJgUnsc9VdWVl8s6pNfcE4pgTh7XS8H5Sr-0E0jZn9VQliVKuYGEuQqUKLxUgROs90MrDK9FdKUOjaG95XIGwYwtxehyrH6MQAcTiPQUu-aAs/s320/IMG_9512.jpg" width="320" /></a></div><br />
The length of slotted angle is supposed to be a guide for the straight cut along the side. I abandoned it immediately, as it was not helping me.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzsmtZbuhTXBZTKyzUAchPoHdPmBRM1CPkTU27yvVH_ymduiwE9igRcpB7eJcbnUgTGlC2hV4p0KfzERf3xNsUJ69q3putcWC98ifpnfNXHiZnGaCKe16_nGdullZKNqSR4r7wKqayDcM/s1600-h/IMG_9516.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzsmtZbuhTXBZTKyzUAchPoHdPmBRM1CPkTU27yvVH_ymduiwE9igRcpB7eJcbnUgTGlC2hV4p0KfzERf3xNsUJ69q3putcWC98ifpnfNXHiZnGaCKe16_nGdullZKNqSR4r7wKqayDcM/s320/IMG_9516.jpg" width="320" /></a></div><br />
Any decent shop teacher would give me a D for those "straight" edges, but it <i>was</i> cut.<br />
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The next step was to grind the edges that will be welded nice and straight and flat, and brush all the old grotty appliance enamel off the inside.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_NPAGpjzl6vYRZOK7bloOVEfAOTQgEgHDfRPcl0_QZNtDpgPoI4uopUyt_pwcGiy2TVARrQIxElYXosD8MoI1Cu81048Bstyw0ZXT_LuBn7JOybCtc0yB_fRVNGjQOCywrtXo5dMnQRk/s1600-h/IMG_9519.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_NPAGpjzl6vYRZOK7bloOVEfAOTQgEgHDfRPcl0_QZNtDpgPoI4uopUyt_pwcGiy2TVARrQIxElYXosD8MoI1Cu81048Bstyw0ZXT_LuBn7JOybCtc0yB_fRVNGjQOCywrtXo5dMnQRk/s320/IMG_9519.jpg" width="320" /></a></div><br />
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Getting straight bends without a bending brake has been a challenge. What has worked least poorly so far has been to clamp firmly the fixed portion of the workpiece between two lengths of angle to keep it rigid, and then use a third length to force the bend. A box bending brake would work much better.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi64Aq-aw_mb3TPSBJELy-_cQCIhYpkvkkYvz_kQz4GqGDkjDAz835Bbml3fqTFCSO_IR1H3r6wVYWPMvvrBuKQDGA9qGqNlUUJU7llevAtV0g25qnOYFdUK1Ok2DZ-9QrxtoHShyf0OaA/s1600-h/IMG_9522.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi64Aq-aw_mb3TPSBJELy-_cQCIhYpkvkkYvz_kQz4GqGDkjDAz835Bbml3fqTFCSO_IR1H3r6wVYWPMvvrBuKQDGA9qGqNlUUJU7llevAtV0g25qnOYFdUK1Ok2DZ-9QrxtoHShyf0OaA/s320/IMG_9522.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKsQXWPjoaMOpXfSZSLWpFrdxKooty0xZVxhIPz6xEVgrmMdrlqm38rib2Z7YsGm3olU85iq6zEt2YajsXkMzIZ6yAevlJM2AanZQYltBEMd4e7CXhx0uTYGYGG70s5vYixadTsuHdInY/s1600-h/IMG_9525.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKsQXWPjoaMOpXfSZSLWpFrdxKooty0xZVxhIPz6xEVgrmMdrlqm38rib2Z7YsGm3olU85iq6zEt2YajsXkMzIZ6yAevlJM2AanZQYltBEMd4e7CXhx0uTYGYGG70s5vYixadTsuHdInY/s320/IMG_9525.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMHKZ02fmGe5xJmGbxnuCc9oOd3HKysrxFiOMiyEYk7KqfcxAIJKXkwsNdrTYRIyytBcVHOTCN8Jt5qEr9WtbO8lnLVXYUzN0hfoiDNI0uir85F29aVWOiGMMX5r8D2IJo0z4rkV0T5rI/s1600-h/IMG_9526.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMHKZ02fmGe5xJmGbxnuCc9oOd3HKysrxFiOMiyEYk7KqfcxAIJKXkwsNdrTYRIyytBcVHOTCN8Jt5qEr9WtbO8lnLVXYUzN0hfoiDNI0uir85F29aVWOiGMMX5r8D2IJo0z4rkV0T5rI/s320/IMG_9526.jpg" width="320" /></a></div><br />
I clamped it closed and welded it up. Here's how it came out.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK2IK_q_lx7kxnOv56alvoXWFJyK2oTU81k2sBTEYxcaAzxws2kPO5nKPbabhpyD3XEHsdVfbxTzAZJqODTJlOQJrliL_IzLaXgoaaLkHiTuZuvF6OLR2v3I64T7Nxjk02aSsjCdf7XKI/s1600-h/IMG_9527.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK2IK_q_lx7kxnOv56alvoXWFJyK2oTU81k2sBTEYxcaAzxws2kPO5nKPbabhpyD3XEHsdVfbxTzAZJqODTJlOQJrliL_IzLaXgoaaLkHiTuZuvF6OLR2v3I64T7Nxjk02aSsjCdf7XKI/s320/IMG_9527.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCtFNypDpgF6MCpw8ODQtZu-FxgRCA8DbomfWJ3co3JoF4gKmDanVhChx6GZDuLGM2WsOxJcnOSmmuCJMIlkeS525mi4d6NFky46zhw7w97vzquazxiT2p0vA0GN_2oRzMQ3Q3wmZVZu4/s1600-h/IMG_9528.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCtFNypDpgF6MCpw8ODQtZu-FxgRCA8DbomfWJ3co3JoF4gKmDanVhChx6GZDuLGM2WsOxJcnOSmmuCJMIlkeS525mi4d6NFky46zhw7w97vzquazxiT2p0vA0GN_2oRzMQ3Q3wmZVZu4/s320/IMG_9528.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0r62JLjgFcdzzDV-dwZHZZBpj4f7I9RgqmWsshPC_UswI4vGYTmhjLrdjtGAIVcanw4q-RsecAORK73tNaj-9itRoiOzTHVot1cpTdzmj6cBFcerz26Cl4mgHp6oPAGG17e2r3Im32Dc/s1600-h/IMG_9529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0r62JLjgFcdzzDV-dwZHZZBpj4f7I9RgqmWsshPC_UswI4vGYTmhjLrdjtGAIVcanw4q-RsecAORK73tNaj-9itRoiOzTHVot1cpTdzmj6cBFcerz26Cl4mgHp6oPAGG17e2r3Im32Dc/s320/IMG_9529.jpg" width="320" /></a></div><br />
Looks nasty before cleanup! Grinding welds flush on sheet steel this thin is risky, so I didn't dare take them down completely. But it did end up looking quite presentable.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjo2a4GlGghC_Ub6yDDPz0t5PvnBsUlLpHM8FamagCKpsibfOWMtK-lRjWjXYCMlfDeCKhJrjPz8U_qmSUqxZ3Tg2ixm5kfvJ-2G-QWftqWcr4lk5OrIlXzPjDo88fAWUPLMxFTxJgjmyY/s1600-h/IMG_9545.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjo2a4GlGghC_Ub6yDDPz0t5PvnBsUlLpHM8FamagCKpsibfOWMtK-lRjWjXYCMlfDeCKhJrjPz8U_qmSUqxZ3Tg2ixm5kfvJ-2G-QWftqWcr4lk5OrIlXzPjDo88fAWUPLMxFTxJgjmyY/s320/IMG_9545.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi78HgdxjuKYsnYsr7iYw7HofOAG484z_BsPITx-VN306OJ0Ta-ca_BZk0bPNGFgFpeDSKW5WGDEADky2-mdoATkib1tscP50tIiD-GR2zNGVGrhrFRQ1bp1igtjBTqqq-x9_yl5dAexK4/s1600-h/IMG_9546.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi78HgdxjuKYsnYsr7iYw7HofOAG484z_BsPITx-VN306OJ0Ta-ca_BZk0bPNGFgFpeDSKW5WGDEADky2-mdoATkib1tscP50tIiD-GR2zNGVGrhrFRQ1bp1igtjBTqqq-x9_yl5dAexK4/s320/IMG_9546.jpg" width="320" /></a></div><br />
And in fairness, here's the ugly side.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVogLW8kmcgU6jzSGB6upTcf1avzPCd_la6AkAt4hCzH2hv3_RHAOSOv2f_YQMPgP5siodU-7r-ta7zmFjaZ0Hc51fnJKW8gzBEAwFj0biO6zLJsAg6xIy-XFZKu3lZg58SuA7H5z6BfA/s1600-h/IMG_9549.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVogLW8kmcgU6jzSGB6upTcf1avzPCd_la6AkAt4hCzH2hv3_RHAOSOv2f_YQMPgP5siodU-7r-ta7zmFjaZ0Hc51fnJKW8gzBEAwFj0biO6zLJsAg6xIy-XFZKu3lZg58SuA7H5z6BfA/s320/IMG_9549.jpg" width="320" /></a></div><br />
Here it is mounted on my drum kit.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV8AhVkbTQIas2DlwoNTJgn_3qLJupBXHXpH4y19PP9S0RkfVP-29jP6u_AHBVZvNDzI8sRMGttuzGYr_zV62sq6J8nOnct1OG6h7Hi8oFVJPbvI2DTM_WiHXrbnOylNhn3UYxgfhdt58/s1600-h/IMG_9553.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV8AhVkbTQIas2DlwoNTJgn_3qLJupBXHXpH4y19PP9S0RkfVP-29jP6u_AHBVZvNDzI8sRMGttuzGYr_zV62sq6J8nOnct1OG6h7Hi8oFVJPbvI2DTM_WiHXrbnOylNhn3UYxgfhdt58/s320/IMG_9553.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSDBfcGgD_dd5EzQze5N5ig9yYDZcYjZb7x0_EEpxokEwxRIFdV-PGGiGj1PcQ_9Fyvck_HUkhiAg2ab5L8gVEaiehDtpv-n_Oqa8CXyB6_TjklcEsEMJQ7IdxT-ZiWfLt_6DcW22XmAM/s1600-h/IMG_9567.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSDBfcGgD_dd5EzQze5N5ig9yYDZcYjZb7x0_EEpxokEwxRIFdV-PGGiGj1PcQ_9Fyvck_HUkhiAg2ab5L8gVEaiehDtpv-n_Oqa8CXyB6_TjklcEsEMJQ7IdxT-ZiWfLt_6DcW22XmAM/s320/IMG_9567.jpg" width="320" /></a></div><br />
It sounds different from other cowbells I've played. The steel is 23 gauge, much thinner than usual, and I've opted for longer and narrow as a result. But it has a very clear distinction between low and high notes, and a nice ringing low tone.<br />
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<object classid="clsid:d27cdb6e-ae6d-11cf-96b8-444553540000" codebase="http://fpdownload.macromedia.com/pub/shockwave/cabs/flash/swflash.cab#version=8,0,0,0" height="28" id="divplaylist" width="335"><param name="movie" value="http://www.divshare.com/flash/playlist?myId=10256216-2a0" /><embed src="http://www.divshare.com/flash/playlist?myId=10256216-2a0" width="335" height="28" name="divplaylist" type="application/x-shockwave-flash" pluginspage="http://www.macromedia.com/go/getflashplayer"></embed></object>Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-1902408641586792782.post-20577524742535119212009-12-08T16:59:00.000-05:002009-12-08T16:59:11.452-05:00Toaster sculpture!Our toaster broke. Everyone was very sad. Except me.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_Bqi_A0FKwW8GWTT-3LYX4qutaOC-0-CD3QB4VB-lbQ8mTOmQnAtW9MSPP56M1Tstos2nv2dmpIjNlkOiVmn7Hnp870TcD-SgxGfJnpzpXQUWjjHh8bcITIS7NdEuf0fwzMHKw_iigSo/s1600-h/IMG_8880.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_Bqi_A0FKwW8GWTT-3LYX4qutaOC-0-CD3QB4VB-lbQ8mTOmQnAtW9MSPP56M1Tstos2nv2dmpIjNlkOiVmn7Hnp870TcD-SgxGfJnpzpXQUWjjHh8bcITIS7NdEuf0fwzMHKw_iigSo/s320/IMG_8880.jpg" /></a><br />
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Nothing personal, Oster T. Toaster, but I've got an oxyacetylene torch with your name on it. I set myself the challenge of making something interesting.<br />
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I misled Oster about his name, by the way. But I do like what it does say.<br />
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So, after discarding the non-recyclable plastic and saving the wiring and electronics for other purposes, here's what's available.<br />
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When there are obvious faces, it seems foolish to ignore them.<br />
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First time with the cutting attachment. It is, apparently, wildly oversized for the thin steel I am trying to cut. The preheating flame burned through immediately without oxygen, so I just melted the face away instead. Not the intended result, but an interesting one.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguhBV6-b8FGA9IKNRRgmKTzUeDkpRplhXiskL955xIyxmuPrt0FRwgvNdppbaMmpf7NcwzhCOnWr1RM0-n52I0B3LkfIQwnQHisCbZYvMBN91eFFdXQAvPcwxDnK2EP-tE2jZU6fu2zNM/s1600-h/IMG_8890.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguhBV6-b8FGA9IKNRRgmKTzUeDkpRplhXiskL955xIyxmuPrt0FRwgvNdppbaMmpf7NcwzhCOnWr1RM0-n52I0B3LkfIQwnQHisCbZYvMBN91eFFdXQAvPcwxDnK2EP-tE2jZU6fu2zNM/s320/IMG_8890.jpg" /></a><br />
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And the direction is set.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiggjzieAx0BZbyZZz1JHqVO2XUz49wKdVhi3SKwh-cKF8WVu0Cr3xKHzWFxMJcRsrAQxVZRWHCVg4F23nQk-JkL2lUS1wdTnWcVLK9c0km0LwunM3A_nBKFHj5FJ1tBA49Z7I-OU6ormw/s1600-h/IMG_8894.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiggjzieAx0BZbyZZz1JHqVO2XUz49wKdVhi3SKwh-cKF8WVu0Cr3xKHzWFxMJcRsrAQxVZRWHCVg4F23nQk-JkL2lUS1wdTnWcVLK9c0km0LwunM3A_nBKFHj5FJ1tBA49Z7I-OU6ormw/s320/IMG_8894.jpg" /></a><br />
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Hmm. No.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8VJQcifV1S1YTRUTzcD-YGSRXQxqWbU88vu9GCUgd76T-eafwax7nKqHVKhJwUf8eg39LF2MWWkPMYIMps1QIWIVOC-9okNJD6nJ15taFzhGQ-yRS_FnMm3nuq6c0xNa9_jZN_SR4Y1I/s1600-h/IMG_8898.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8VJQcifV1S1YTRUTzcD-YGSRXQxqWbU88vu9GCUgd76T-eafwax7nKqHVKhJwUf8eg39LF2MWWkPMYIMps1QIWIVOC-9okNJD6nJ15taFzhGQ-yRS_FnMm3nuq6c0xNa9_jZN_SR4Y1I/s320/IMG_8898.jpg" /></a><br />
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Yes. OK, time to find the rest of the body parts. Hmm...<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyeR93GeQbKQU34lNrl34WeE2Wj2fsuqXUZdlg2ZiTb_GkV6Gk5f05sibC8q3mVFXSh12jw3K9Bj5d6WExpsXbUtBHBFCqNDcevaVYELDq9Z0560izA5UsbUQ8oXGDtfeOhx4_w1UJzgI/s1600-h/IMG_8901.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyeR93GeQbKQU34lNrl34WeE2Wj2fsuqXUZdlg2ZiTb_GkV6Gk5f05sibC8q3mVFXSh12jw3K9Bj5d6WExpsXbUtBHBFCqNDcevaVYELDq9Z0560izA5UsbUQ8oXGDtfeOhx4_w1UJzgI/s320/IMG_8901.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2uoY0GcAkiHKCeECwpVYZVDgTVsQsVljxULL0wWp9tganVAPGDH4dRlG18Tk1mK4hollyiRfdVKR68gioTpudstGAt_i5yIrCnohB9UUGuoosBgH3uIggjj5fvwWdU7emniz6GwdZB4o/s1600-h/IMG_8902.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2uoY0GcAkiHKCeECwpVYZVDgTVsQsVljxULL0wWp9tganVAPGDH4dRlG18Tk1mK4hollyiRfdVKR68gioTpudstGAt_i5yIrCnohB9UUGuoosBgH3uIggjj5fvwWdU7emniz6GwdZB4o/s320/IMG_8902.jpg" /></a><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN9gjXZa6ZgX3dQSPtC_0sB4xJJx34uw4bRqkJt7NNLafUqUyOWQ_oqOQE4F28J-Yw9n8Oy9qIELQp1LquKxV1R2bsieoqkCvNJgNl9ZEV-1VZjT78ajNSGtrevJeZNXQkH0mYPMl1le4/s1600-h/IMG_8906.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN9gjXZa6ZgX3dQSPtC_0sB4xJJx34uw4bRqkJt7NNLafUqUyOWQ_oqOQE4F28J-Yw9n8Oy9qIELQp1LquKxV1R2bsieoqkCvNJgNl9ZEV-1VZjT78ajNSGtrevJeZNXQkH0mYPMl1le4/s320/IMG_8906.jpg" /></a><br />
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And there it is! Time to switch the torch to the welding tip and braze this guy together.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKIEqz8kvuc50tI1f_Oy-S2YQU8lAy76tD4hCCcErPOYX17f80iRpJOhRKM9Gt_q2BCw5-L5hDh3Ly5LNshMccVTBvB4J1EG-v0dlWYKlnMcML9V6IannOwWKZK2zlv8g0w_k1aQgTcC8/s1600-h/IMG_8908.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKIEqz8kvuc50tI1f_Oy-S2YQU8lAy76tD4hCCcErPOYX17f80iRpJOhRKM9Gt_q2BCw5-L5hDh3Ly5LNshMccVTBvB4J1EG-v0dlWYKlnMcML9V6IannOwWKZK2zlv8g0w_k1aQgTcC8/s320/IMG_8908.jpg" /></a><br />
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I'm going to need a bigger quenching bucket.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4ffa_L8dB75LbkAQP6wZq_N3n2ijpBt_8kd5KUwkQPL95t4hv3SjtbBJFMW8dH6idEh0MhWguzK8s5pF_oEIUiBdf3QD_Fd6eN1sV2lAWSU1T0_5kzChLu7gdZN_64YLCKwoYczhFQ4s/s1600-h/IMG_8909.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4ffa_L8dB75LbkAQP6wZq_N3n2ijpBt_8kd5KUwkQPL95t4hv3SjtbBJFMW8dH6idEh0MhWguzK8s5pF_oEIUiBdf3QD_Fd6eN1sV2lAWSU1T0_5kzChLu7gdZN_64YLCKwoYczhFQ4s/s320/IMG_8909.jpg" /></a><br />
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This seemed like the point where adding things would make it worse and not better. So it's done!<br />
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There are more and better photos of the cleaned up sculpture <a href="http://www.etsy.com/view_listing.php?listing_id=36325208" target="_blank">in my shop</a>.Unknownnoreply@blogger.com0