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Monday, May 15, 2023

Segmented Bowl – # 11 Refine Bowl’s Shape, Cutting Top Free & Finishing Top Lip

While adding the last few layers onto the top half stack and waiting for the glue to cure between layers I started to refine the bottom half of the bowl's layers exterior down to its near finished size.  This process starts by taking the finished diameter at the glue line between layers off a drawing and laying them out on the bowl.  The drawing below shows the finished inside and outside radius of all those points.

Below the top photo shows the drawing, bowl and the tools including my homemade large diameter calipers needed to mark both the current diameter and final desired diameter on each of the layers.  The bottom photo shows a closer view of the current dimension at the top and the desired finished dimension (underlined) at the bottom.

With the dimensions marked the bowl is mounted on the lathe and steps are cut just a little larger than the finished bowl diameter.  These will act as depth guides when turning.  The three layers on the left do not have the depth guide cut as I want to keep the maximum thickness there for stability when turning the layers farther out.  Those layers will get turned later once the outer layers are finished.

Here I am back working on the bowl’s top half.  At long last the 21st and final ring is glued and clamped in place to the top half.  I know someone is going to ask why is there only 16 layers listed in the above drawing rather than 21.  That’s because layers 8 and 10 are really made up of two thin layers that I chose to list as “a” and “b”.  Since they are so thin there is going to be very little difference in their finished diameter.  Also, layer 9 is made up of the 4 center feature rings and I will blend their final profile by eye as the turning progresses.

After the top’s last rings glue has cured, I took off all the clamps, mounted it on the lathe and removed all the steps between the layers to get a very rough shape.  Once roughed out the top half is set on the in-progress bottom half to get a general idea of what the bowl is going to look like. 

From that point on the work of refining the shape based the outside diameters alternates between the top and the bottom halves.  Once I get close to the desired dimensions the final shape is determined by setting the halves together and looking at the bowl to see where changes need to be made.  The left bowl is an intermediate step and the right represents the near final shape before they get glued together.  However, once the two halves are glued together there will be more refinement done particularly along either side of the final glue joint.

 Turning the inside of the top and bottom smooth and the wall to a constant thickness is next.  Also, the inside and outside diameters where the two halves meet need to be matched as close as possible.  The outside is more forgiving since once glued together the bowl can be mounted in the lathe and any irregularities blended together.  However, any misalignment on the inside is way harder to correct.  Here is the top finished and ready to be parted or cut off the lathe’s faceplate and mounting block.   

The first step in parting off the top is to drill a small hole (red arrow) through the waste in the top layer as in the top photo so I can see exactly how much of the wall remains holding the bowl on.  The bottom photo has been cut down so there is a band of just under 1/8” thick holding to bowl on and that’s as close as I want to get. 

To finish removing the bowl a Japanese pull saw is used.  The removed top half along with the saw is in the top photo and the bottom photo is a close view of the resulting rim.  The red arrows show the thickness of all that was holding the piece on.

To clean up the cut edge the piece needs to be mounted back on the lathe with the rough edge facing out.  That’s done using a jumbo set of jaws mounted to the scroll chuck shown in the top left photo.  In operation when the chuck is closed it pulls the eight rubber bumpers at the perimeter down to tightly to hold the piece in place shown in the bottom left photo.  The right photo shows the top edge cleaned up.  It’s not finished but is set up for use when the top and bottom pieces are glued together.

Doing a dry fit for the gluing is next which when done looks like the photo below.  However, before I could do that the wood mounting block that’s on the just cut off face plate needs to be modified and an adapter has to be made (red arrows).

First is to modify the wood mounting block that’s screwed to the just cut off face plate by turning the mounting block down some to make a tenon that will fit inside the bowl’s top opening.  During gluing the tenon will center the top half of the bowl and the flat face will provide the surface where the clamping force is applied. 

The second piece is an adapter that goes between the tailstock which is on the right side of the dry fit photo above and the modified mounting block/face plate.  One end of the adapter is sized to just fit inside the threaded neck part of the face plate that screws to the lathe headstock.  The other end needs to have a taper that will match up with the #2 Morse taper inside the tailstock.  Turning the left side of the adapter is easy but the taper on the right side is a bit more difficult since the taper angle needs to match the taper inside the tailstock.  After some measuring and a bit of fine-tuning fitting the piece fits snuggly in the tailstock with no wiggling.

Next Up – Gluing Halves, Final Shaping & Finish Selection

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