Some of you may have seen a
post from a student asking if we could help.
Sent Tim a PM and received back a representation of the shape of the item, and a spread sheet with all the station diameters on it. Like every millimetre, from one end to the other.
Quite intrigued with the idea of working to strict measurements I asked if the sizes could be redone at 1cm stations. A few hours later the new spreadsheet file was on my computer.
I had a couple of turning jobs to do over the next few days, finished one. Then received a phone call and had to put the second off, so I decided to make a start on the 'horn'.
If I had possessed a thicknesser it would have been easy, as it was I had to thickness each layer on the lathe. Fairly easy with two lathes. Cut the blanks 5mm over size for thickness, the wide end I had to butt join two pieces for the width. I had been given the option of using MDF, but I hate that stuff and the mess it makes so used Sycamore. After gluing I mounted the piece on a screw chuck, trued up one face and cut a recess for my chuck. Mounted the blank in the chuck trued the second face then measuring carefully took it down the 30mm thick from the start mark. Cleaned up the outer edge to the widest dimension on the spreadsheet. Then finally turned a small 2mm deep recess in the centre.
Mounted the next piece between centres, trued up one face with a spigot to fit the recess in the last piece, and glued together. Once dry I trued up the next face at 30mm thickness, also leaving a small register recess for the next piece.
I continued in this vein leaving each layers diameter as per drawing, until I had built up the full size.
Looking at what I had left I decided I could manage to form the full shape by eye, working from 20mm stations, so I commenced to measure and use a parting tool until I had a width station at every 20mm along the length.(Some where 10mm apart because of the 30mm layers) I then rechecked the measurements twice more before I picked up my gouge.
I ripped the wood away until I was left with the basic horn shape, but still wearing a row of 'V' cuts of which the base of the cuts were the station marks. I then proceeded to gently work away with the long edge of the bowl gouge, slowly matching the form to the corners of my station marks. Until I was finally left with this.
I quite enjoyed the challenge, but there was a couple of heart stopping moments when I though I had taken too much off,
but it was all OK. The turning part was fairly easy, the hardest part was getting all the stations correct first, so I spent a lot more time than I should checking. But at least I didn't have to re-do it. 8)