|Project by Sam Shakouri||posted 01-19-2010 09:27 AM||2242 views||5 times favorited||5 comments|
THIS IS TO BE REFERENCE TO THE CONTEST VOTERS
I was asked by many L Js to give some detiles about how I put the Twisted Daughnut together. I am more than happy to do it now.
Before you start, you have to be sure you have enough patience to the end, because you are not going to see any result before, at least, a week or two.
OK, let me talk about, paricularly, my daughnut. It is 300mm dia, the round tube is 100mm dia, so the central hole is 100mm dia as well.
The tube is made of 24 small rings, each ring is made of 12 segments.
First, I cut 144 segments of wallnut and 144 of rock maple. by that I ended up with 24 small rings, each ring has to be cut down to 15 digrees ( 7.5 digrees at each side ) to make the big tube ring.
NOTE: If you build a long tube and cut it into 24 small rings at 15 digrees, you will manage to glue them into a daughnut and save alot of timber but the two colours will sit on themselve and it will be striped
daughnut not twisted. The choice is yours.
I had to work individualy on each ring and cut it 15 digrees, 7.5 digrees from each side AFTER twiste it 5 digrees of the previous ring position, so each colour would sit off on two thirds of the next segment of the same colour.
For that reason, I had to number the rings 1 to 24 and glued them in the same order when they were ready. Otherwise the twisted lines would be broken in many places.
Gluing those 24 rings was another difficult process because they were runing toward thier heavy sides uncontrollably. I glued every six rings and then glued the four quarters together.
At last the daughnut was ready to go to the lathe.
I had no any kind of chuck to hold that unusual shape and size, so I had to build a special chuck. I enlarged my 140mm dia metal face chuck to 340mm dia by attaching it to a disc of plywood serouned by flexiabl fence and squeezed the daughnut in it by using 20 huge ruber bands.
That home made chuck exposed only one quarter of the daughnut tube to the chisel. So I had turn it around to turn the other inner quarter. The inner half of the tube was turned, but the outer half was not.
For that I had to build another special chuck to hold it on the lathe from the already turned center as showing in the picture.
The last part, I had to repeat all those ’ 4 movements’ another 2 times, one for sanding and one for polishing.
I’m sorry for those who intend to turn thier own daughnut. they probably, just by reading this article, will give up before they start.
After all, it is just a chalange you have to accept it if you like to do it.
I enjoied every minute of this project.
-- Sam Shakouri / CREATING WONDERS WITH WOOD.....Sydney,Australia....