CYLINDER MAKING #1: Cylinder ends

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Blog entry by BertFlores58 posted 07-09-2012 09:02 AM 2241 reads 1 time favorited 4 comments Add to Favorites Watch
no previous part Part 1 of CYLINDER MAKING series Part 2: Splitting the cylinder. »

Probably the best technique in making a cylinder is making first the top and bottom. Then make the wall by following the contour of the ends. I made the two cylindrical ends by using a circular jig with mounted router using 1/8” spiral bit. Then I make a shoulder edges on same jig using 1/4 straight router bits.

I do not have a picture of the round ends showing the dado edges. After the ends were both made, I selected a veneer tha can be wrapped around. I nailed brads to temporarily hold the fitting to the shoulder of the circular ends. Masking tape holds the joints of the veneer’s end.

My original plan is to make a single wrap of veneer and glue to it strips of 3/8” wide and 1/8” thick vertical or along the cylindrical lateral side. It will be a difficult work since the joint for the strips will be creating an angle of 360/40 strips/2 = 4.5 degrees. So, I decided to use a Barbeque skewers made from bamboo. Though the skewers are not really of same diameters, they are still on acceptable limits. As you can see, I glued already 2 rods on the sides to start with and will go on until I covered all the sides. I will see whether it will be a good finish afterwards meaning strong and has good texture, otherwise, an outside veneer can be used. This is a good tip…. As there is no fixed plan on this… BETTER TO DECIDE ON THE CHANGE THAT AN ALTERNATIVE OR AN OPTION IS AVAILABLE FOR THE UNEXPECTED.

I already had faced a lot of challenges in this project. I thought it would be easy.
1) I could not push the veneer from inside to have uniform shape. I just rely on the spring back force of the veneer and the pressure of the tape from the outside. I have to wait now to let dry the glue on the bamboo skewers. 2) I made the shoulder on the ends (only 3/16”) that cannot hold much of the veneer that is why I use a brad nail. I like to use a tucker but the uneven edges of the ends gives a lot of problems. And 3) I need to start gluing the skewers on one reference point and not staggered because I am avoiding gaps.

This is an experimental work and have several challenges in me…. such as:

1. How can I cut the box so that the other will become the lid?
2. I need to make the lipping on the sides which is circular… HOW?
3. I need to reinforce the circular edges (for example a banding or moulding) as there are some evidence of splitting…. How?
4. I had never seen a circular lid that is fitted with a hinge however I am to ambitious to reach this goal.. How?

A lot of unanswered questions and if you will suggest, I will follow and try… What is important is for others to learn the impossible construction of a cylinder made from wood. If it is plastic or steel then it would be easy.

Till next time, Thanks for reading.

-- Bert

4 comments so far

View Roger Clark aka Rex's profile

Roger Clark aka Rex

6940 posts in 3463 days

#1 posted 07-09-2012 12:02 PM

Great info Bert, well done

-- Roger-R, Republic of Texas. "Always look on the Bright Side of Life" - An eyeball to eyeball confrontation with a blind person is as complete waste of Time.

View SPalm's profile


5320 posts in 3910 days

#2 posted 07-09-2012 12:21 PM

Hey Bert, good for you.
I just love playing around and seeing if things work out.
It is looking great so far.
And it got me thinking.


-- -- I'm no rocket surgeon

View BertFlores58's profile


1698 posts in 2950 days

#3 posted 07-09-2012 01:28 PM

Just to give a little update.. here is the picture of the lateral side after fitting 50 pcs of skewers:

Just imagine, I just covered about 1/3 part. The skewers are 1/8 inch in diameter each… Getting good and becoming strong. Till next.

-- Bert

View Cozmo35's profile


2200 posts in 3064 days

#4 posted 07-09-2012 08:12 PM

Very cool idea Bert. Thanks for posting.

-- If you don't work, you don't eat!.....Garland, TX

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