|Project by PASs||posted 03-15-2011 04:51 AM||1837 views||0 times favorited||8 comments|
I was at a craft show a few weeks ago and a Scout Master asked if I could make a staff.
I make walking canes, but my Craftsman lathe only handles about 36 inches, so a staff would require two pieces joined together.
I wasn’t crazy about the joining issue due to alignment concerns but gave it a try.
The staff is 69 inches tall, made in two part with the bottom turned with a 3/4 inch dowel end that I epoxied into a receiving hole in the top half.
Both parts were rough turned on my Craftsman lathe to round the wood, then placed in my Craftsman Router Crafter (with a Dewalt router) to cut the pineapple spiral for the top and the reed (or is it flute) for the bottom.
I then put the parts back on the lathe for sanding and applying a 2 pound shellac sealer. I rough sanded with 80 grit sanding pad on a 3 inch drill pad in a Dewalt 3/8 inch drill, followed by 220 grit and finished with 320 grit. I didn’t sand any of the router cuts as they were smooth enough (but a sanding mop is also on the make-it list.)
Next I drilled the hole for the joint using a 3/4 inch Forstner bit in an Allied drill press. A lesson learned was that I should have marked the center before I cut the square end off because finding center was difficult (gotta make that center finding jig one day). Also ensuring the hole was plumb to the staff was difficult because the drill press is on a dolly and the shop floor isn’t even, so a centering and holding jig is also now on the list.
I then epoxied the parts together with 5 minute epoxy, sanded the joint smooth, applied another coat of 2 pound shellac to the sanded area, and polished the whole staff using the Beall system.
The wood is Indian Don’t Know.
The whole project took about 4 hours from square wood to polished staff with the exception of about 2 hours trying to get the hole drilling set up.
Additional photos are available here:
-- Pete, "It isn't broken, you just aren't using it right."