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Closed Segment Project 1441

stuart johnson said:
Glenn, I don't know why I sent block instead of disc but I do like the idea.
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Stuart, for the sake of waste it would be better to start building rings from the biggest to the smallest as I could keep trimming my centre disc smaller thus only using one piece of material. Going smallest to biggest I have to sacrifice a new piece for each layer. They do come out easily so I will save them for the next project.
 
martyn said:
I too like to see these processes followed out by others, i will be following this project with you, please keep up the post, its very interesting.
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Thank you Martyn, it is a fun project from beginning to end. Kind of nerve wracking when you touch it with chisels though!
 
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When I am ready to glue up a ring I line up my pieces in groups of 10 (because the pattern is 6 groups 60/6=10). It's also a great opportunity to check the pattern layout as all 6 groups should look the same. This is Ring #3.

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And this is how it looks after clamping.

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After flattening it is added to the main body.

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1321 pieces remaining.

Ring #4 is flattened using my Jumbo Jaws. I check it with a straight edge to make sure it is flat.
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This is the main body with ring 3 on and flattened and ready for glue to attach ring #4
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Ring #4 attached.
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Now 1260 pieces remaining.
 
Now 1140 individual segments to go.
Ring #5 is on and ready to be flattened.

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When I flatten the ring on the main body I have to ensure that I get the thickness down to the required .187 "
 
Ring #6 I built today and I took a few extra pictures to show how I clamp the segments from the top as well to ensure the ring is flat to minimize turning or sanding to the proper thickness.

Once glued I put light pressure on the hose clamp, put a piece of wax paper over the ring, place the MDF block on top of the ring and apply a few clamps with light pressure . Then I snug up the hose clamp and then tighten the clamps. A bit of overkill on the clamps but as they say "you can never have enough clamps".

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I should have mentioned I finally got my hands on some Titebond Type II Extend glue. So far I like the consistency and it certainly does give you an extended work time. I even remembered to give it a stir, who knows how long it has been sitting.

I also have Ring #7 in clamps. The balance of my shop time today was spent cutting segments. Pieces for ring 8-13 are waiting in containers. I will typically add two rings in a day but have sometimes done 3. I will wait a minimum of 2 hours after applying a ring before I will flatten it and add the next ring.

So my posts will slow down a bit as I am caught up with what I had done to date. I was a bit behind in getting the post going.
 
Thanks for sharing. I really like these project posts. I pick up tips from them all the time.
 
mfisher said:
Thanks for sharing. I really like these project posts. I pick up tips from them all the time.
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Thanks Mike. I'm not sure my way is the right way or just some sort of convoluted method. I like to solve issues without having to spend money or have to buy special tooling.
 
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Glenn, I like these als. It's always good to see how someone else solves a problem and seeing their procss
 
Got an early start this morning . Flattened Ring #7, Dressed face on Ring #6 and attached Ring #7 to the main body.

This means 361 pieces done, 1080 to go.

I have Ring #8 ready to go except for the flattening. Now I will go back to the shop and sand fuzzies off for the next two rings, number 9 & 10. It's soon time to do a rough turning so I may do that between the next two.

The pattern is starting to come together.

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Just goes to show what can be done when you have made good round circles. It was be great to see the completed project.
 
mfisher said:
Just goes to show what can be done when you have made good round circles. It was be great to see the completed project.
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Hi Mike. I physically just finished rough turning the first 7 rows. I'll have a few pictures here shortly. The circles really help me.
 
Row #9 and Row #10 is in clamps so I may even get another row on today.

The only thing that may slow me down is the snowfall that is happening right now and is supposed to dump 6" of the white stuff on us.:(

I also have row 11-13 already cut in pieces. I don't think I have enough tulipwood to cut anymore segments. Hopefully tomorrow the roads will be good.
 
One thing in my process of using the circles is that they are sometimes difficult to get out. The plywood I use is 3/16 thick which is just shy of the thickness of my rings. When I take it out of clamps I position it on a very flat surface and press down on the centre circle to push it down ever so slightly. You can hear the glue crack. You then work it around pushing very easily bit on two occassions I broke the ring. It did break clean on a glue line so a little dab of glue and back in a clamp for a bit. I did fix one with CA and some accelerator.

The next time I buy material for the centre I think that I will get the 1/8 thick MDF. This will give me a bit of extra room to push down on the centre to loosen it up.
 
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