|Project by DaveTPilot||posted 10-04-2014 08:21 PM||958 views||0 times favorited||2 comments|
I was asked by my mother-in-law to make a gavel block for my father-in-law. He is becoming Master of the Lodge and was already given a gavel for another honor.
She said to just grab a block of scrap wood and throw something together real quick. Nothing fancy, just something with a side to which she could possibly add a name plate.
She knows me better than that after 12 years of marriage to her daughter. I hope she and he like it.
Wood: Jatoba (A small square block I bought years ago from the “scrap bin” at Woodcraft. I knew I’d use it one day.)
Process: I used a circle cutter on my drill press to mark the outside diameter and to give me a line to work up to with my plunge router. I just free-handed it. That always makes me nervous but since I was doing the recess first, a screw up would be easy to start over.
After cutting the circular recess, I squared the block making the circle dead center. Then I cut the legs by making several passes over the table saw with my dado stack installed. Leaving the fence in the same spot and starting with a square block, the legs are all the same size. I beveled the edges with the router table. I then cut the grooves at the top of the legs to give them some definition using a v-groove bit on the router table.
I installed the emblem with some epoxy and filled the recess with Glaze Coat so the emblem sits below the surface. I finished the rest of the block with Glaze Coat as well.
Problems: Glaze Coat can be a real pain in the A$$ to work with. Even after 2 pours, there were some major blemishes. The stuff seems to just arbitrarily decide it will not flow into a given area and leave a crater. I missed it before it dried. I don’t know how for the life of me as I studied it very closely under all kinds of lighting including natural light. I did my entire counter top at my old house an didn’t have this much trouble.
The Cure: I wet sanded the top and any drips with 180 grit then followed with 600 grit. I then tried coating it with a water based poly but it came out awful. Did not level and left streak marks from the brush. I then remembered that you are not supposed to use a brush with water based poly. D’oh! I just read that a few weeks ago too!
Back to sanding. this time only with 600 wet paper. I was out of time and left with a relatively smooth but very dull surface. Out of desperation, I grabbed my can of Clear Gloss Spray Lacquer. I had to spray outside but it was humid as all heck in SWFLA. When I sprayed it, it looked awesome for 10 seconds then clouded badly. I quickly brought it into the 76 degree A/C cooled house. It dried perfectly clear in about 5 minutes or less.
I hit it with a second coat and the same thing happened but the results were the same also. Very happy. Crisis averted. :)
-- How valuable is time to a person who spends his disparaging the beliefs of others? --David Berthelette www.pilotwoodworks.com