introduction to segmented woodturning - jim … to segmented woodturning course number 95505001 mt....

IntroductiontoSegmentedWoodturningCoursenumber95505001

Mt. Diablo Adult EducationA division of the Mt. Diablo Unified School District

Serving Life Long Learning

One Santa Barbara Road, Pleasant Hill, CA 94523 (925) 937‐1530

2 © JL Rodgers, Inc. 236 Briar Drive

Martinez, Ca 94553

Rules of classroom conduct

Rulesofclassroomconduct

Alwaysmaintainasafeworkenvironmentforyourselfandotherso Alwayswearsafetyglassesorfaceshieldsasrequiredo Adviseinstructorofanysafetyconcernsorissues

Cleanupattheendofeachclasso Yourworkarea/latheo Theclassroomfloorsandtableso Sharpeningcentero Replacealltools/accessoriesintotheproperlocation

Alwayssigninonarrivalo Adviseinstructorifyouplanonleavingearly

Beresponsibleforyourownpersonaltools/equipment


Martinez, Ca 94553

Turning Segmented Vessels You will learn:

How to build a sled for cutting accurate segments How to assure good, positive joints How to align and assemble a vessel How to turn and assemble the final project

What you will do:

Build a ring flattening stick Construct a “quick start” project from a provided design

Build your own cutting sled Build segmented holding tool

There will be many project activities that may not be completed during the class session requiring you to complete certain steps off line. Equipment you will need:

A table saw, chop saw, or radial arm saw o 60-80 tooth finish cut blade only – recently sharpened

Belt/disk sander o 60-80 grit fresh belt/disk

Lathe with a 10 inch swing or larger

Supplies you will need1

Project wood for the first 10-ring hollow vessel o 2 BF of 4/4 stock of one hardwood o ¾ BF of a contrasting 4/4 hardwood of similar density o Black veneers

Two 3 inch face plates with 1 x 8 Small bottle of Titebond glue or equivalent Straight edge or square & bright light Ring sanding stick (instructions to build to be provided) A flat glue-up surface and paste wax Selection of hose clamps (from local hardware store –discussed in first session)

Additional items you may also desire to have for your convenience Jet or One Way live center system and live center to faceplate adapter accessory (3/4 x 10 to 1

x 8 adapter)1 Available from Oneway or their distributors Ring alignment cones

o www.curttheobald.com o www.segmentedturning.com

1 Completed projects will be turned on 1 x 8 lathes in the MDAE classroom. If your personal lathe at home uses a different thread (e. g., 1¼ x 8) you may wish to consider purchasing a thread adaptor for your own thread size and turning the project at home.


Martinez, Ca 94553

Source notes

Things you need

Lathe with a 10 inch swing

Two 3 inch faceplates with hardwood glue blocks attached

Glue block should be cross grain hardwood

TS or chop saw equipped with a 60‐80 tooth finish cut blade and a zero clearance throat plate

10 – 12 inch disc sander with a fresh 80 grit disc

Alternate make a flat sanding disk for use on the lathe

Flat glue up surface Waxed heavily

Small, bright light & straight edge Hardware store For checking flatness

Small bottle of TPVA wood glue Local hardware store

Project wood Local lumber provider Two contrasting colors of similar density 2 BF of one species ¾ BF of second species

A selection of hose clamps Local hardware store Be sure to check the brand logo and only buy one brand.

3/8 – ½ inch wood dowel cut into 1” lengths

Local hardware store Used for assembling rings with ½ ring method

Things to make

Sanding stick Use 80 grit sand paper on a flat hardwood stick

Segment hold down tool Use an Allen wrench installed in a wood handle and sharpened

Cutting sled for saw Plan provided for a table saw which can be adapted to a chop saw

Nice to have (but not required)

Oneway live center Oneway Manufacturing or woodturning dealer

Its nose cones will assist in ring alignment and accept useful attachments

One way live center faceplate adapter

Oneway Manufacturing or woodturning dealer

Screws onto the TS live center from Oneway and allows attachment of your faceplate

Ring alignment cone www.curttheobald.com Screws onto the Oneway live center to align rings up to 8 inches ID

Segment vessel calculation software

www.woodturnerpro.com http://www.segmentedturning.com/www.turnerwood,com

Assists in completing all math calculations and vessel drawings


Martinez, Ca 94553

SegmentedWoodturningResources

Quick Starts Some students may want to start now, by pre-reading background materials. To this end I have posted a series of articles initially written for The American Woodturner to my webs site: www.jlrodgers.com. Also this handout can be found at the same site.

Segmented plans and kits developed by Bud Latven are sold through Craft Supplies and Packard Woodworks. Some of these plans are for more complicated designs, but are a good way to learn about some of the tricks. Note that each plan contains full scale drawing and are rated from easy to difficult (1 – 5).

Tutorials Tutorials are also available on line from Kevin Neely (www.turnedwood.com) who has probably taught more segmented turners that anyone and Verified Software (www.segmentedturning.com)

On the transitional vessels and other materials from this class see by site: www.jlrodgers.com

Cutting sled In order to accurately cut segments you will require a fixture that cuts the desired angle repeatedly, allows for segment edge length measurement, and provides safety when cutting smaller pieces. For detailed information on building a cutting sled download complete instructions for my sled from AAW or one of the others processes available:

My sled construction plan can be found at www.jlrodgers.com Kevin Neely’s Turned Wood www.turnedwood.com Verified Software acumiter sled www.segmentedturning.com/acumiter.htm

Books There is a lot of useful information provided in written form; the most recently published provide the most complete descriptions for the segment process.

The Art of Segmented Wood Turning, Malcolm Tibbetts, Linden Publishing, 2005 Woodturning with Ray Allen, Ray Allen & Dale Nish, Fox Chapel Publishing, 2004 Segmented Turning, Dennis Keeling, The Tauton Press, 2012

Also available are:

Segmented Turning, A Complete Guide, Ron Hampton, Guild of Master Craftsmen, 2003 Segmented Turning, A Good Start, Bill Kandler, Verified Software, 2004 Segmented Turning, William Smith, Schiffer Publishing Ltd., 2002 Laminated Designs in Wood, Clarence Rannefeld, Lark Books, 1998 Southwest Pottery – Anasazi to Zuni, Allen Hayes & John Blom, Northland Publishing, 1996 Fine Woodworking on Faceplate Turning, Taunton Press, 1987


Martinez, Ca 94553

DVD’s There are a limited number of videos available

Lessons in Segmented Woodturning, Volumes One – Eight, Malcolm Tibbetts, www.tahoeturner.com

Introduction to Segmented Turning, Curt Theobald, www.curttheobald.com

Segmented Patterns, Curt Theobald, www.curttheobald.com

Segmented Turning – a Learning Experience, Bill Kandler, www.segmentedturning.com

Software suppliers Stave calculations http://stavecalc.logiztix.net/ Segment calculations for one ring at a time www.turnedwood.com/ Calculations for open segment work www.the woodturnerscatalog.com Integrated design and layout for open and ring construction www.segmentedturning.com This is the one I use http://woodturnerpro.com/ General woodworking software including layout http://www.woodbin.com/

Veneer Sources Wood cost comparisons http://www.verifiedsoftware.com/goodturns/woodcosts.htm Constantine’s http://www.constantines.com/ Certainly Wood www.certainlywood.com Hearn Hardwoods http://www.hearnehardwoods.com/ Woodworkers Resource http://www.woodworkerssource.net/index.html


Martinez, Ca 94553

Segmented Project Completion Instructions

This instruction sheet describes the basic steps in constructing a ring segmented vessel. While projects may vary the work steps will remain basically the same. Some open bowl project will only require one face plate. When turning the vessel or bowl concentrate on obtaining the correct shape by referring to your drawing. Disregard the voids between the rings and concentrate on the curvature; as you approach the correct shape and diameter the voids will disappear. Prepare stock

o True and square stock o Rip stock to the required Board widths on Cutting Summary o Cut stock to length (remember add 3 inches for safety)

Prepare to cut segments o Check the saw for proper alignment o Set fence for 15 degree o Set stop for correct segment edge length o Cut a test ring, readjust if necessary

Cut segments o Cut segments by flipping the stock o Number the segments as they are cut o Repeat for all twelve segments and all rings o Sand each segments with 180 grit to remove any burrs

Build rings o Build half rings first

Assemble a ring in a band clamp Prepare two thin shims Glue segment 1-6 and 7-12 only creating two half rings Assemble half rings into band clamp Insert two shims between segments 6-7 and 1-12 (the unglued edges Tighten clamp while keeping the ring flat and the shims centered Wipe away excess glue

o Complete ring Disassemble half rings from band clamp and examine for flatness with a

straight edge With a stationary disk sander, flatten the half rings and recheck with straight

edge Glue exposed ends and re-clamp

o Flatten rings Thickness sander

Flatten one side until no irregularities are visible Reverse and flatten opposite side

Disk sander Hold each ring to the disk and sand one side flat Check with a straightedge for flatness

Belt sander (not recommended) Carefully sand one side until no irregularities are visible

o Lay ring flat on the sander and slide carefully across the belt o Rotate the rings slightly and repeat


Martinez, Ca 94553

o Check for flatness with a straight edge o Final thickness and ring flatness will be completed after the ring

is glued to the project Assemble project

o On each of two faceplates, attach a glue block of approximately the diameter of the foot and one approximately the diameter of the top neck ring to be affixed

o On the lathe, true up the face of the attached glue block o Then sand flat with the ring flattening sanding stick o Check for flatness with a straight edge and bright light o Glue the project base to one face plate centering carefully o Glue the top ring to the second face plate centering carefully o When the glue is dry re-flatten each assembly as described above o Proceed from both the bottom and the top of the vessel adding one ring, allowing the

glue to dry, flattening and sanding The base assembly should be completed through the widest ring of the vessel

only; on the other face plate complete the balance of the vessel o Flatten the final level on both assemblies

Turn project o Turn the exterior

Mount the base assembly on the lathe headstock Place the other assembly (vessel top) on the tail stock live center and press the

two halves together with the tail stock quill Turn the exterior shape DO NOT REDUCE THE NECK OR FOOT TO ITS

FINAL DIMENTION AT THIS POINT Mark the alignment of the top/bottom section with a pencil to allow for

repositioning later Remove the half vessel from lathe

o Turn interiors Mount each vessel portion on the lathe and complete the interiors Assure the wall thickness of the abutting rings are the same wall thickness

o Assemble the vessel Remount the base assembly on the headstock and the top assembly on the

tailstock and align the pencil marks Pull the top half away slightly and add glue and recompress to clamp After glue is dry, re-true the exterior of the vessel to correct any alignment

errors if necessary Complete the exterior shape of the neck reducing its diameter to the desired

size Part off the face plate holding the top of the vessel

o Complete the vessel Turn the inside of the neck carefully and at higher speed to completed shape After the neck interior has been opened, clean up any projecting materials from

the recently joined area Reduce the foot of the vessel to its final diameter (You may choose to add a

cone support at the neck area during these operations.) Sand the exterior of the vessel and apply finish to your satisfaction Part off base from primary faceplate


Martinez, Ca 94553

Building A Table Saw 15 Degree Segment Cutting Sled

Stock required o 24 x 24 sheet of ½ inch quality plywood o Hardwood for miter guides o KD 2 x 4 x 48 inches for cross supports o ¾ x 3 x 24 inch hardwood for miter fence

Prepare stock o Cut stock to size

1 each 18” x 24” ½” ply cut dead square 2 each ½ x ¾ x 24 inch strips for miter grove guides 1 each ¾ x 3 x 24 inch hardwood segment fence 1 each 2 x 4 x 24 inch rear cross support brace 1 each 2 x 2 x 24 inch front cross support fence

o Collect additional supplies 2 each 1½ bolts with head diameter less than ¾ with washers and nuts Wood screws 1 inch ¾ inch Forstner bit Glue Toggle clamp with ¾ inch mounting screws One each stick on measuring tape (RH) Fine ink pen Square Vernier calipers

Assemble sled o Sand 18 x 24 base on both side o Place miter guides in TS miter slots on top of spacer (to raise them above TS surface) o Bring TS fence to 12 inch setting, lock in place o Place glue on miter guides and set 18 x 24 on top aligned with fence o Add weight and allow glue to dry

Add cross supports o Carefully align front and back cross support braces o Glue and clamp front and back cross support braces

Add saw kerf o Clean up any glue and scrape slides until there is a smooth operation on the saw table o Wax the back o Raise saw blade and cut a kerf through he rear cross support and 12 inches into the

sled Mount hardwood segment fence

o Clamp Miter segment fence accurately in place using a protractor to set approximately 15 degree angle to saw kerf, clamp firmly

o Flip sled over side-to-side (read fence is still in the rear) and drill one hole in each miter guide through which to attach the hardwood segment fence

o RH hole is 4 inches from front edge of sled and LH hole is7.5 inches from front edge. Drill only through the hardwood miter guide

o Continue holes with smaller drill (diameter of the bolts) completely through clamped fence

Complete segment fence assembly


Martinez, Ca 94553

o Turn sled right side up remove the segment fence o Elongate one of the drilled holes to 1 inch long o Bolt segment fence in place readjusting accurately to 15 degrees o Add toggle clamp to the segment fence approximately 6 inches to the right of the saw

kerf o Cut a short strip of hardwood with the sled to use as a segment stop

Calibrate sled o Set TS blade to an accurate 90 degrees vertical with a good straight edge o Rip several strip of hardwood to 1 inch o Clamp stop in place with the toggle clamp o Carefully cut six segment using sled o Snugly assemble the six pieces against a straight edge and check; there should be no

gap If there is a gap on the outside of the semicircle of segments, the angle is too

oblique Adjust the segment fence towards the rear of the sled (away from the

operator)to increase the angle If the gap on the inside of the semicircle, the angle is too acute

Adjust the fence rearward (towards the operator) to decrease the angle o Repeat by cutting another 6 segments and retesting o When the six segment test appears perfect, cut a set of 12 segments

Assemble a full ring by clamping the segments together with a hose clamp Check for gaps Readjust fence as needed to decrease the gaps to zero

o When calibration is complete, screw segment fence firmly in place with several wood screws on both sides of the saw kerf

Completing the project o Recut the stop with the newly calibrated sled o With vernier calipers, set the position of the stop at exactly 2 inches from the right-

most tooth of the saw blade, clamp firmly with the toggle clamp o At a convenient location on the stop, place a fine line with an ink pen and square o Align the stick-on measuring tape’s 2 inch mark with the line drawn on the stop o Stick the measuring tape in place


Martinez, Ca 94553

Rear of

Elongated hole with washer

Stop cut at 15 degrees


Martinez, Ca 94553

TRIGONOMETRY FOR SEGMENTED TURNERS Angle functions are useful in calculating the setup of sleds for specific angles. When accurately determined the calculations can set the segment fence precisely. The longer the measured line the more accurate the set up will be. To calculate the proper angle you need to use the appropriate trig function; here they are: Sine =Opposite/HypotenuseCosine=Adjacent/HypotenuseTangent =Opposite/Adjacent

Angle Sine Cosine Tangent 30 degrees

(6 sides) .5000 .8660 .5774

22.5 degrees (8 sides)

.3827 .9239 .4142

18 degrees (10 sides)

.3090 .9511 .3249

15 degrees (12 sides)

.2588 .9659 .2679


.1951 .9808 .1989


.1305 .9914 .1317

Setting up a new segment fence

Draw a horizontal line across the full width of the sled.

Calculate the distance up the RH side of the sled by using the tangent of the desired angle

Measure up the right hand side of the sled the exact number of inches from your calculation and mark.

Draw a line from that mark to the beginning of the horizontal line. Align the sled fence to that line for the proper angle.

Example: 12 segments requires a 15º segment cutting angle Sled with is 24 inches Tangent 15 degrees x 24 inches = RH length to calculate 0.2679 x 24 inches = 6.43 inches


Martinez, Ca 94553

¼ x 12 x 2

Hardware: 4 each ¼ ‐ 20, 2 inch Carnage bolts

4 each ¼ ‐ 20, through hole knobs

4 each ¼ inch washers

5 each # 6 x ¾ inch wood screws

Roll double‐sided carpet tape

¼ inch up cut router bit

5/8 inch up cut router bit

Tools: Plunge router

Table saw

Drill press

Square, protractor

WedgieSledTMConstructionPlan

Cutcomponents:

Cut MDF & plywood components to size from drawing above

¾ x 12 x 14 MDF

¾ x 12 x 2

¾ x 12 x 2

3/8 x ¾ x 12 in hard wood


Martinez, Ca 94553

Drillfences:

Tape fences and plywood

together, layout holes locations from

drawing

Drill holes on the drill press in fences

and template as indicated

LayoutMDFbase:

On the back side of the base mark location of the two pivot holes

Insert a fence into the pivot hole with a ¼ x 20 bolt

Using the fence; inside edge, mark the pivot limits at 0 and 30 degrees as shown below


Martinez, Ca 94553

Routethepivotslots:

Install a ¼ inch straight cut bit into the router

Place the double sided tape on the plywood template and mount the router by extending the 1/4

inch bit into the ¼ inch hole at 4 inches form the end; press down firmly to seat the router onto the

template

Place a carriage bold through the opposite end hole (one inch from the end) and into the hole in the

base

Set the router depth to slight greater that the thickness of the MDF base

Clamp the base, router/template combination to a sacrificial backing

Route a groove from the 0 to 30 degree reference marks on the base extending approximately 1/4

inch beyond each mark

Repeat for the other fence location

Routethedadoslots:

Replace the router bit with a 5/8 inch bit and set the maximum depth to ¼ inch

Re‐route both groves to create the clearance for the carriage bolt heads and clearance for the pivot

hole also

Assemblethesledcomponents

Constructthemiterslotguiderail:

Cut the hardwood strip to snugly fit into your miter slot – test the fit

Assure that the hardwood guide is less thick the miter slot is deep – mill or sand the thickness as

necessary

Drill and counter sink 3‐4 holes in one side to accommodate the mounting screws

Attachthemiterslotguidetothefencesystem:

Place the Wedgie sled on the TS with the face slightly extended over the saw blade about 1/16th inch

Bring up the TS Miter Fence to touch the rear side of the sled, lock it into place and remove the

Wedgie sled

Inset the miter slot guide into the miter slot raising it slightly above the table saw cutting surface

Add double‐sided tape or a thin layer of glue to the miter slot guide rail

Place the Wedgie Sled against the locked fence and then down onto the miter slot guide and press

firmly

After the Sled is firmly connected (or the glue dried) turn the sled over and screw the miter slide

firmly into the Wedgie sled with #6 wood screws

FinalAdjustments:

Assure that the Wedgie sled slides smoothly on the saw; sand or scrape any areas where the sled

binds

Assure that the fences move easily into the routed slots: sand area where binding occurs

Raise the TS blade and carefully trim the front edge of the sled


Martinez, Ca 94553

Accessories:

A zero clearance TS insert is needed

Modifying the zero clearance insert with an additional “ramp” to prevent the segments engaging the

blade will be an additional aid

A segment measuring stop is also required; it should allow segments to fall freely from the TS blade

and not allow them to get trapped.

Below is one example of how they may appear.

For more information and to see videos of use and construction go to: www.Segeasy.com


Martinez, Ca 94553

Veneer/Ring Glue Press

Materials

1. Melamine sheet 2. Melamine disks various sizes to maximum ring

diameter 3. 2 x 4 KD, construction grade 4. Veneer press screw, Rockler, Grizzly, etc 5. Stove bolts, wood screws

Construction: 1. Construct a square base from 2 x 4 stock

a. Add short cut offs to corners for reinforcement and to act as feet

b. Screw all components together c. Add a center cross support to support

center 2. Install Melamine square on top surfaces with smaller wood screws 3. Through bolt two 2 x 4 uprights to the center of left & right sides 4. Laminate together two 2 x 4 into a cross beam

a. Allow approximately 1 ½ inches on each end of the lower laminated beam to project on either side

b. The longer length should be slightly less than the clearance between the two uprights created in step 3

5. Mount press screw into the center of the cross beam

a. Drill clearance hole in center to fit screw

b. Mount screw into hole from the bottom

6. Complete upright supports a. Extend screw to near maximum

length and set onto Melamine surface created in step #2

b. Measure where cross beam contact uprights and mark location c. Screw two 2 x 4 pieces to upright from the melamine surface to the marks d. Set cross bean on new upright supports e. Retract veneer screw to near minimum extension and measure clearance between press deck

and screw f. Add additional 2 x 4 sections of the this measured length on top of cross beam screwing them

into place on the uprights g. Continue to the desired height of press is achieved


Martinez, Ca 94553

Notes & cautions: Note that the photographs included in the write up do not necessarily conform to my

latest thinking. Dimensions for the glue press can be adjusted to meet the maximum ring diameters

that you require All 2 x 4 sections added to the uprights must be thoroughly screwed into place since

a lot of sheer stress will be applied during operation One or more cross beams must be added to the initial under framing to provide

support of the mid portion of the press so it won’t flex If a longer veneer screw in purchased, less (or no) “notches” will be needed Use KD construction timbers to prevent wood movement and shrinkages due to

drying The “plastic” surface of the melamine sheet will allow for waxing to prevent glue

form sticking – this will be needed! Purchase additional; Melamine disks to match the ring sizes you will pres so that they can be stacked to equalize pressure during the glue


Martinez, Ca 94553

Student Projects A first project is an open bowl requiring only one faceplate and four rings. When turning this project be sure to follow the shape of the drawing failure to do so may cause your base curvature to be too tight and the wall thinness near the base to be very thin. Strive for ¼ inch wall thickness.


Martinez, Ca 94553

Second and third projects (or what every time will allow) require two faceplates. One half of the project is assembled on each faceplate – bottom up and top down. Make the division between the top assembly and bottom assembly at the widest portion of the project – the mechanical center.


Martinez, Ca 94553


Martinez, Ca 94553

OpensegmentconstructionOpen Segment construction is both easier and more involved. Less accuracy of the cuts is required

as pieces don’t fit against each other. However the assembly requires a method of positioning the individual

pieces at specific angles around the circumference of the “ring.” This is accomplished by positioning fixtures

and indexing of the rotation. More details on the three different methods for this style of construction can be

found at: http://www.jlrodgers.com/pdf/open‐segment‐woodturning‐1.pdf ,

http://www.jlrodgers.com/pdf/open‐segment‐woodturning‐2.pdf, and http://www.jlrodgers.com/pdf/open‐

segment‐woodturning‐3.pdf. (Note: This is a three part presentation on the methods for open segment

construction)

Resources open segment construction:

Segmented Wood Turning, William Smith

Segmented Turning, Dennis Keeling

Driskell fixture: http://www.finewoodnthings.com/open_segment_glue_up_2.htm

Bill Smith fixtures and indexing files: http://jlrodgers.com/EdResources/Bill%20Smith%20Files/

Indexing plates:

Iron Fire plate 14, 36, 48 & 60 holes www.Ironfirellc.com

Alisam Engineering 90, 120, & 144 holes www.Alisam.com

JL Rodgers Woodturning 360,288, 96 www.jlrodgers.com

SegEasy plates: www.segeasy.com

Software for designing open segment construction:

Woodturner Studio, http://www.jerrybennettart.com/products.htm

WoodturnerPro, www.woodturnerpro.com

Segment Project Planner, http://www.segmentedturning.com/


Martinez, Ca 94553

Row Type # Segs.

Board

Thickness

Diameter

(OD)

Diameter

(ID) Board Width

Economy

Board Length Miter Angle

Segment

Edge Length

8 Dark Wood12 0.75 3.58 1.38 1.13 9.7 15 0.96

7Open Segment

Light Wood 24 0.75 4.44 2.5 0.97 11.1 5.5 0.43

6Open Segment

Light Wood 24 0.75 4.68 3.5 0.6 12.49 5.5 0.45

5Open Segment

Light Wood 24 0.75 4.68 3.69 0.5 12.69 5.5 0.45

4Open Segment

Light Wood 24 0.75 4.61 3.38 0.62 12.26 5.5 0.44

3Open Segment

Light Wood 24 0.75 4.32 2.75 0.79 11.23 5.5 0.42

2Open Segment

Light Wood 24 0.75 3.88 1.75 1.07 9.59 5.5 0.37

1 Disk Dark Wood0.75 3.31

SimpleJarOpenSegmentProject

FirstOpenSegmentProjectSimpleJarheight6inches


Martinez, Ca 94553

introduction to segmented woodturning - jim … to segmented woodturning course number 95505001 mt....

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