From ball to the star inside dodecahedron #2: Making plugs

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Blog entry by Yuri posted 03-30-2012 01:33 AM 2000 reads 2 times favorited 5 comments Add to Favorites Watch
« Part 1: First half Part 2 of From ball to the star inside dodecahedron series no next part

I’ve been trying different approach on making plugs to hold peaces together. In the end, I’m down to two products: rubbery silicon and epoxy clay. Both keep size after drying (most important property for me). First I made new “cups”

Here is the small ball 1.5 inch diameter, possibly my next project. Both covered with oil

Epoxy and two layers of fabric (doesn’t need to be strong for now)

Carefully insert dull thin blade and slowly peaces will come apart


Mold was poured into the fiberglass fibre cup and ball was pressed down

Next day, cup is removed

This is how it looks. Very soft on touch.

Because i mixed to much, i decided to make a mold of the old plug

I start looking for something harder then silicon:


Two plugs after drying. Sanded to ball shape

Comparing silicon and epoxy

Plugs removed from the ball

I’m making two more plugs from epoxy clay

Back to the ball shape

I’m going to use five epoxy and one silicon plugs. But from now on I will be making epoxy clay plugs only. It’s big time saving, can be sanded, drilled, turned. Result is “cleaner” and better then wood-wax, silicon, pure paraffin, etc. Just remember to oil the wood.

-- Live to Learn

5 comments so far

View stefang's profile


14971 posts in 2425 days

#1 posted 03-30-2012 12:07 PM

This is a great solution Yuri, especially for this type of turning.

-- Mike, an American living in Norway.

View BritBoxmaker's profile


4587 posts in 2127 days

#2 posted 03-30-2012 01:43 PM


-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View Rob_n_Wood's profile


109 posts in 2440 days

#3 posted 04-29-2012 02:29 AM

I am the Dean of the KISS University
but in this case all I can say AWESOME
Even after reviewing the photos’s it still
blows my mind Excellent job

-- "I predict future happiness for Americans if they can prevent the government from wasting the labors of the people under the pretense of taking care of them." Thomas Jefferson

View mafe's profile


10541 posts in 2180 days

#4 posted 06-04-2012 06:41 PM

Auch – this is amazing!
Good thinking.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

View Jim Jakosh's profile (online now)

Jim Jakosh

14426 posts in 2197 days

#5 posted 09-03-2012 12:28 PM

Wow, you are a very creative craftsman. I hope you are going into engineering. You have such original ideas!! You’d make a great inventor. Nice going , Yuri!!

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

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