Stave Vessel Design Construction Tom Kenyon May 2012

Stave Vessel Design & Construction Tom Kenyon May 2012

The Art of Segmented Wood Turning By Malcolm Tibbetts • • 10” is too Tall - looking for about 6” 6/4 wood required for staves prefer 4/4 2

First Prototype • Symmetrically scaled plan to 6” high • Simplified construction – Eliminated veneer layers – Eliminated multi layers splines 3

Revised Design • • • Prototype too round Top out of proportion to the body Center divider too thick Created lip for top/body joint Second prototype looked good 4

Parts Neck Top Separator Splines Staves Bottom 5

Stave Cutting Jig Based on Replaceable Throat Sled My Friend! 6

Stave Cutting Jig First Ten Vessels 7

Dedicated Segment Cutting Sled Designed to accommodate Bridge City Tool’s Angle Master – Large rear fence opening – Removable segment slide 8

Vessel Holding Fixture • Used for; – Initial glue up of staves – Initial turning of the base – Final turning of the base • • Design from PBS TV show and Malcolm Tibbetts book Duct tape help donuts slide 9

Ring Sanding Jig • • Shown previously in Show-n-Tell Descriptive article posted on Segmentedwoodturners. org 10

Templates • • Templates cut of 1/16” plastic on the laser Outside only one that proved useful 11

Production • Production of 20 broken into three groups - 10, 5, and 5 – Manageable number of parts – Doable task - not overwhelming – Assessed mix after each group • Wood combinations that worked or didn’t work • Appropriate mix • Available material • Timeline (best recollection) – Design started late Sep, done by third week of Nov – Lots of time finding material (tops) and making prototypes, jigs, and templates • Four weeks to the first prototype – One to two days to prepare material - almost independent of number of vessels – Two vessels going simultaneously – About a day for each 12

Parts Preparation 13

Parts Assembly and Glue up 14

Top • • Top opening drilled after finishing - fits tailstock plug - helps alignment during glue up Inside finished with shellac 15

Base/Bottom • • • Lots spinning ! Slow is OK Watch out for those bolt ends! Inside bottom base cut to blend in with bottom plug, also gives reference for turning inside 16

Turning Base Inside & Outside • • Trick is getting a tight fit with top Inside finished with shellac 17

Finishing the Vessel Last step is to make plug to center vessel’s top on the jig 18

All Done ! • • Used General Finishes sealer and oil/urethane Buffed with brown paper sack after a week 19