What is the best way to make this?

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Forum topic by mnausa posted 10-18-2013 03:39 PM 1882 views 0 times favorited 17 replies Add to Favorites Watch
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33 posts in 2342 days

10-18-2013 03:39 PM

Topic tags/keywords: jig question tip walnut shaping arts and crafts

The wood is walnut. 11”x 11”x 3”. I need some ideas on the best way to make about a 100 of these. I do not have a lathe.

-- Mike, Mississippi,

17 replies so far

View bondogaposis's profile


5570 posts in 2914 days

#1 posted 10-18-2013 03:49 PM

Pretty tough w/o a lathe. Router and template, would work but you wouldn’t be able to get that large a radius that way.

-- Bondo Gaposis

View JustJoe's profile


1554 posts in 2601 days

#2 posted 10-18-2013 03:50 PM

What tools do you have?

-- This Ad Space For Sale! Your Ad Here! Reach a targeted audience! Affordable Rates, easy financing! Contact an ad represenative today at JustJoe's Advertising Consortium.

View a1Jim's profile


117790 posts in 4140 days

#3 posted 10-18-2013 03:51 PM

There’s a fellow on Ljs named Izzy who has made some thing like these on the table saw with a jig, you would have to modify his jig to hold a square blank but I think it’s possible. You might even ask him for help he loves making jigs.

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2303 posts in 3048 days

#4 posted 10-18-2013 03:52 PM

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333 posts in 2741 days

#5 posted 10-18-2013 03:58 PM

I’m not sure that core box bits come in a radius large enough for it but as Bondo mentioned, a template with a circle cut out and then use a large core box bit to achieve the curve. Might have trouble going that deep though.

-- Ben from IL

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117790 posts in 4140 days

#6 posted 10-18-2013 04:03 PM

If your considering the round templet an the core box bit you can use one of these to get the depth you need.

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Clint Searl

1533 posts in 2924 days

#7 posted 10-18-2013 05:05 PM


-- Clint Searl....Ya can no more do what ya don't know how than ya can git back from where ya ain't been

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Jim Baldwin

56 posts in 2921 days

#8 posted 10-18-2013 05:22 PM

Buy a lathe or order them from someone who has a lathe. Any conceivable milling operation will still leave this rough and unsanded. For that operation alone you would need a lathe. A machinist lathe including faceplate and swing tool setup would do the job otherwise it’s CNC or a hand turning operation. At 11X11X3 times 100, this is not a small router-bit project.

-- Jim Baldwin/[email protected]

View theoldfart's profile


10985 posts in 3014 days

#9 posted 10-18-2013 05:46 PM

A router on a pendulum would do it.

-- "With every tool obtained, there is another that is needed" DonW ( Kevin )

View BTimmons's profile


2303 posts in 3048 days

#10 posted 10-18-2013 06:09 PM

@ theoldfart – That sounds like an episode of Jackass right there.

-- Brian Timmons -

View PaulDoug's profile


2265 posts in 2267 days

#11 posted 10-18-2013 06:51 PM

BTimmons, I don’t thing the method you give the address to would work for the bowl he wants, that guy had a round blank to start, the bowl Mnausa wants if square. Not saying you couldn’t build an more elaborate jig that you could put a square blank in and turn it. Like a bigger circle on the stationary base and a insert circle with a squire for the blank cut into it. Sure would be easier to borrow a lathe….

-- “We all die. The goal isn't to live forever; the goal is to create something that will.” - Chuck Palahniuk

View a1Jim's profile


117790 posts in 4140 days

#12 posted 10-18-2013 07:39 PM

Paul after thinking about it, I think since Mike’s bowl is square it would still work in a round in a round jig just having the corners touch as long as all the blanks fit properly. Bottom line a CNC would make quick work of it.

View Natalie 's profile


367 posts in 2530 days

#13 posted 10-28-2013 01:57 AM

You guys are all amazing how you can problem solve and make stuff without the right tools. That is what I so admired about my dad and now about my husband.

So, even reading your posts I can’t get my head around that. Sorry, you gotta make 100 of these? Buy a lathe.

-- Natalie - My mind is like a bad neighborhood, I don't like to go there alone.

View bobasaurus's profile


3616 posts in 3747 days

#14 posted 10-28-2013 06:52 AM

Have you considered a rosette or shaper cutter in a drill press?

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

View realcowtown_eric's profile


619 posts in 2500 days

#15 posted 10-28-2013 07:41 AM

The router on the pendulum sounds like a possible choice for me.

Just make sure it is wobble free,(no sloppy joints in the kig you’ll have to envision and make)
Get a diamond hone stone to keep the bit sharp to minimize sanding.

A dull bit could turn a productivity profit center into a time consuming and expensive kludge as you try to get the inset smooth.

A sloppy jig could turn 100 pieces of walnut to absolute crap in an hour or so.

The rosette cutter ain’t a bad idea, but thats a whack of wood to shear off with a rosette cutter. I’ve done a similar thing with a ground to shape spade drill for a golf ball rack, bit thats way smaller.

I kinda like the idea of making a rotary rack for the TS, clamping it in place, and then raising my TS blade into the wood (counting the turns…) and then further smoothing it out with the router pendulum system, -but maybe not…. you may be able to go straight to sanding….(old bowling ball wilth silicon grit epoxied to it perhaps, if that suits the fit, ) or maybe even turn a ball made of laminated MDF on the lathe to the precisely desired radius and then epoxy silicon grit to it . Finish off with some of them 3m scuffing balls.

Just my thoughts, good luck to ya.

I love these kinda ideas getting to fruition.

I hope you quoted enuf to cover yer risk. A systemic FU would cost you 200bm of walnut. You cannot afford to waste even one piece to mistake. Methinks yer anus is gonna be puckered every step of the way. Mine would be. Moreover with 12/4 walnut- which ain’t gonna be on the shelf of the local borg. Some of the thicker walnut I have runs about 19$/bm. so maybe yer 3” stuff is cheaper in yer locaale, but yer still tallkin around 50 bucks a piece for rough stock, 5k$ in material- and thats not counting waste/fall down- lots of the thicker stuff I have in stock has checking problems.

in my neck of the CDN backwoods, 12/4 is special order…So you don’t want to order any more than you need, Therefore you have to ensure your methodology doesn’t turn that to crap….Hope you get a substantial deposit!

Every two errors gonna cost you close to a hunnerd bucks.

So PLEASE PLEASE do not do this on a wing and a prayer, hoping that our wonderful denizens of this list will provide you the definitive answers to allow you to achieve success at first try!

In Canada, we got gun laws, thank heavens, cause my wife would really want to shoot me if I said I worked for three weeks to turn 5k$ of walnut to firewood, and the client won’t pay for it!

I’m closing my eyes, holding my breathe, and wishing that it all turns out OK

And please ask yerself why in the heck they asked you to make these, as opposed to someone else who may have been making them before? Not like there ain’t a ton of wood fabrication factories in the Carolinas who are just dying for work eh?

That leads me to ask youif you have checked into how good their money is? IE do they pay their bills???

Don’t turn a wheel without a 6k$ deposit (based on my figures) -that’s my opinion., cause it sounds a little on the fishy side of things to me.

Eric in Calgary

-- Real_cowtown_eric

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