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Dance on a Volcano II #2: Cutting Arcs in Wood Veneer

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Blog entry by BritBoxmaker posted 614 days ago 1985 reads 0 times favorited 14 comments Add to Favorites Watch
« Part 1: Design and material selection Part 2 of Dance on a Volcano II series Part 3: The big cover up »

Hello again. I printed out a plan and side elevation 1:1 so

The first thing to do is make a simple jig for cutting circles (arcs) in wood veneer. For this I will be using; an offcut of 18mm MDF, four pieces of 3mm Hardboard (Masonite) and a 6mm dowel.

First drill a 6mm hole 15mm in from two adjacent edges in all the Hardboard pieces.

and a 6mm hole near one end and central in the MDF

Glue the dowel into the hole in the MDF and using a suitable jig, route (with a straight sided bit) the four Hardboard pieces to the required radii; 42, 50, 58 and 66mm.

That’s the jig!

Now to cut some veneer. This is done using a knife. Personally I use a scalpel. When cutting the arcs tape the veneer to the MDF base and cut the lesser of the radii first

The veneer is taped in place so that the same arc centre is used for both arcs to be cut, giving a uniform width over the whole of the piece. Second cut

Do this for all three colours; yellow, orange and red. Four times for each colour. Now the purple segment would have its lowermost tip (side elevation) where the centre of the dowel pin in the jig is so I used the 42mm template freehand to provide some pattern overlap (this will be covered by the black sides, later)

Using a piece of masking tape on the underside I put the pattern together to check the fit.

This looks good so I taped the face side of the three arcs (yellow, orange, red) using veneer tape. This was done for all four sides. I placed an arc on the paper pattern and placed the 66mm radius template over it to perform the cutout in the arc.

This was done for all four arcs, They were taped together, with the purple segments as well and a white (sycamore) centre piece cut (using the edges of the yellow strips as a guide) and taped in. A quick look at the reverse of the pattern shows a fairly good overall fit.

The colours are not uniform on the back as dye penetration through the veneer varied. Using plain veneer the rest of the layer was built out and the result glued to it’s 3mm ply base layer. Its in the clamp drying at present so no picture yet.

Thats all for now

Be seeing you

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com



14 comments so far

View Sheila Landry (scrollgirl)'s profile

Sheila Landry (scrollgirl)

7490 posts in 1525 days


#1 posted 614 days ago

Boy, you are good. I know we all say it all the time, but “you make it look so easy!” That, to me, indicates a true master of the process. Thanks for the insight!

Sheila

-- Contributing Editor, Creative Woodworks and Crafts Magazine, If you like reading my blog, come visit at Sheila Landry Designs http://www.sheilalandrydesigns.com "Knowledge is Power"

View BritBoxmaker's profile

BritBoxmaker

4340 posts in 1641 days


#2 posted 613 days ago

Thanks, Sheila.

You can, of course use the same method for cutting full circles, just extend the jig and templates around for the full 360 degrees.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View jaykaypur's profile

jaykaypur

3264 posts in 1013 days


#3 posted 613 days ago

Good job on this and way outta my league but I do know what you are doing and how you are doing it, so my mind is still somewhat working!! This is going to be a really nice looking piece once finished.

-- Use it up, Wear it out --------------- Make it do, Or do without!

View SPalm's profile (online now)

SPalm

4761 posts in 2487 days


#4 posted 613 days ago

Hey Martyn, Looking good.
And wow, are those colors brilliant. What a neat idea.

Steve

-- -- I'm no rocket surgeon

View Roger Gaborski's profile

Roger Gaborski

144 posts in 2353 days


#5 posted 613 days ago

Martyn,
Very nice results and I will try this soon. Nice extension to the rectangular geometric shapes I have been working with.
Roger

-- Roger Gaborski, http://www.gaborski.com

View Sodabowski's profile

Sodabowski

2002 posts in 1438 days


#6 posted 613 days ago

What Sheila said.

-- Holy scrap Barkman!

View BritBoxmaker's profile

BritBoxmaker

4340 posts in 1641 days


#7 posted 613 days ago

Fresh out of the veneer clamp

Well that looks OK. So now to start cutting the black, outer, layer.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View patron's profile

patron

12977 posts in 1946 days


#8 posted 613 days ago

well aren’t you somebody
and isn’t this something

great process
good lesson

only first sip of morning coffee
so far

so i will hold off commenting
till it makes my fingers move again

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View sras's profile

sras

3784 posts in 1734 days


#9 posted 613 days ago

Looking good!!

-- Steve - Impatience is Expensive

View oldnovice's profile

oldnovice

3638 posts in 1973 days


#10 posted 613 days ago

Sheila said it all!

I don’t know if this has ever been asked but what the veneer wood?

-- "I never met a board I didn't like!"

View BritBoxmaker's profile

BritBoxmaker

4340 posts in 1641 days


#11 posted 613 days ago

The veneer is Sycamore, the English variety, as is the solid wood that will be used for the outer, black, skin of the box. This wood is a creamy white in colour. Its a very cheap hardwood and is considered in some parts to be like a weed in the way it grows, almost everywhere. All the wood is dyed with Chestnut, spirit stain. The finish will be spray Acrylic.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

View BertFlores58's profile

BertFlores58

1644 posts in 1527 days


#12 posted 613 days ago

An extraordinary technique on this project. The design arc-pillars is extremely difficult to cut. Martyn, you make it very easy. A new way again… I like most is the arc was cut.

Cheers.

-- Bert

View Roger's profile

Roger

14177 posts in 1409 days


#13 posted 613 days ago

Wowza!

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View BritBoxmaker's profile

BritBoxmaker

4340 posts in 1641 days


#14 posted 610 days ago

Thank you all. Onwards and upwards or as Churchill used to say, KBO.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

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