Thought I would share a fun project I did several years back. Hope you enjoy.

Step One: Cut walnut and ash stock into small squares, 12 walnut, 20 ash.

 

 

Step Two: Drill holes using jigs to insure accuracy - different jig for walnut and ash pieces.

 

 

 

Step Three: Set up table saw to cut at proper angle and cut all walnut pieces into pentagon shape.

 

 

Step Four: Reset table saw to cut hexagons at proper angle and cut all ash pieces.

 

 

Step Five: Make several extra pieces in case you mess one up later.

 

 

Step Six: Make sure you have a friend to drink beer and watch while you're working.

 

 

Step Seven: Glue and tape.

 

 

Step Eight: Relax, watch the glue dry.

 

 

Step Nine: Remove tape, light sanding, wax your ball and close up shop for the night.

 

 

Step Ten: Do it again the following day using tape to minimize tearout.

 

 

Step Eleven: Give the best of the two to your soccer star daughter for her 13th birthday and keep the other for yourself.

 

So that's how it's done!!! Thanks! Love the jigs! What are the metal bars used for?

They were used in the making of the metal drilling guides/plates. Basically, you use them to lay out the hexagon and pentagon pattern to insure the holes are drilled in the correct place on the metal plates. Once you have the plates, you no longer need the bars - but I've held on to everything just in case I want to do it again someday.

Richard - noticed that the project came from a magazine. Would you share name an edition please????? Looks like a super great project for some schools around where I live.

Thanks again for sharing.

 

 

 

 

Fred:

The article I used as a guide for the project is called "Making a Wooden Soccerball, a Jewel of Precision" by Heinrich Klein and it appears in Woodwork 54, December 1998, at pages 47-54. Being a geek of sorts, I did some additional research into the geometric history of the shape and found it fascinating. I'm no mathematical whiz but it doesn't take one to appreciate the project. It would make a great project for any shop class. Best of luck.

Richard

 

 

Nice~!!

A wood soccer ball up from the archives.

That was super John!