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

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Blog entry by BritBoxmaker posted 11-25-2012 02:39 PM 2193 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)

7886 posts in 1665 days


#1 posted 11-25-2012 02:45 PM

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

-- Designer/Artist/Teacher. Owner of Sheila Landry Designs (http://www.sheilalandrydesigns.com) Scroll saw, wood working and painting patterns and surfaces. "Knowledge is Power"

View BritBoxmaker's profile

BritBoxmaker

4439 posts in 1781 days


#2 posted 11-25-2012 02:50 PM

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

3456 posts in 1153 days


#3 posted 11-25-2012 02:51 PM

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

SPalm

4930 posts in 2627 days


#4 posted 11-25-2012 03:26 PM

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 2493 days


#5 posted 11-25-2012 03:42 PM

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

2081 posts in 1578 days


#6 posted 11-25-2012 03:49 PM

What Sheila said.

-- Holy scrap Barkman!

View BritBoxmaker's profile

BritBoxmaker

4439 posts in 1781 days


#7 posted 11-25-2012 04:22 PM

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

13156 posts in 2086 days


#8 posted 11-25-2012 04:36 PM

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

3928 posts in 1874 days


#9 posted 11-25-2012 06:45 PM

Looking good!!

-- Steve - Impatience is Expensive

View oldnovice's profile

oldnovice

3865 posts in 2112 days


#10 posted 11-25-2012 08:05 PM

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

4439 posts in 1781 days


#11 posted 11-25-2012 08:15 PM

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

1646 posts in 1667 days


#12 posted 11-25-2012 11:10 PM

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

15261 posts in 1549 days


#13 posted 11-26-2012 11:37 AM

Wowza!

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

View BritBoxmaker's profile

BritBoxmaker

4439 posts in 1781 days


#14 posted 11-28-2012 08:08 PM

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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