My segment ring attempt
I want to make some display frames for the Famous Women's Quarters being issues by the mint. I want the frames to be round and made of segments, so here is what i came up with (suggestions and criticisms welcomed).
First, I had to cut the segments and I didn't want to make or buy a sled just yet, so I used my miter gauge. This is an Incra 300 and measures angles down to 1/2° so I wasn't worried about that part. To keep the lengths correct I made a fence with a stop and adjusted it to cut the right length...then I cut 22 of the segments (2 extra, just in case) out of some cherry I had.
Here's how I decided (right or wrong) to turn the ring. There will be 2 layers overlapping to make the joinery easier and I started by making a backer out of floor underlayment (1/4" ply) and gluing (sparingly) the first ring to it. Then put the second ring on top of it.
Then to mount it to the lathe I made 3 pieces, one was a chunk with a tenon to put in my chuck, the second was a back support that got screwed to the tenon piece. Then a front support to clamp the underlayment backer down tight. You can see how these went together on the lathe. I drilled holes in the center of everything to allow me to align everything as an assembly. I put a 1/4" bolt through the holes and then screwed the pieces together.
Now it was time to turn, and since I didn't know what tool to use I went with bowl gouges and an EZ wood rougher. I've never done anything that generated this many chips, I was buried in them by the time i got it roughed out. In this pic, you are looking at the bottom of the frame, the rebate is for the inside piece that holds the coins.
So I sanded the outside and then had to remove the backer to finish it up. I took everything apart and put the frame in some cole jaws to cut off the underlayment backer. This was a little tough, plywood really dulls tools fast. I had to sharpen my gouge 3 times to get the dang thing cut off.
Once the backer was removed I had to clean up the face of the ring and trim some more out of the inside. But I finally got it done.
It's easy to see this isn't perfect, but it was more of a test to see if my plan would work. I want to make 4 of these, one for each year of the program, so I now have a way to go about it. One thing I didn't do was make the rebate for the bottom deep enough, I think I may use the router table to cut that a little deeper with a rabbiting bit. I also don't have a way to put a cover on this, like glass or plexi. I just couldn't come up with something that I thought was manageable. Sorry to drag this out, I hope you could make it to the end.
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