The CAD model
Cut the segments using a cutting jig on the miter saw
Sand with a sanding jig
This ensures they are all the same size. A disk works better than a belt for this since it's flatter and more rigid
Glue the segments. Soft steel wire is used for clamping. Note the precision digital angle measuring tool
Mount the piece in the CNC router to finish the center hole
Cut each piece into three slices using the carbide resaw blade on the bandsaw. Note the pusher and angle support that keep things under control
A jig was made on the CNC router to hold the slices for drum sanding
The same jig was also used to hold the top pieces in place for drilling
The CNC cut the center hole a bit undersized. Hand fit using the spindle sander
Put tape on the back of a piece of 1/4 MDF
Use the CNC to cut spacers
The pieces are held by the vacuum fixture and the tape
The finished spacers
Turn the shaft on the lathe. It must be accurately sized for its entire length. Glue the end spacer on the shaft, and after drying, remove any inaccuracy on the lathe
Assemble the pieces on the shaft. Numbers help keep the pieces in order
The finished glue-up. The top 3 sections are not glued
The top sections are not glued. They are attached with a screw, washers and a clamping disk
The complete stack
The top clamping disk fits the lathe chuck perfectly
On the lathe, ready for turning
Basic shape finished
Now, cut the grooves
This is a tricky and delicate operation. The large pieces on a thin shaft cause it to chatter a bit when cut
It would be really easy to ruin it now. So go really slow and careful
After sanding. The three top pieces are separated for the next operation
The ball cutout is a 3 axis, inside sphere. Test it first on MDF
Now, route the real thing
The finished cutout
Clamp the segments for the ball
Sand with a jig
Final hand sand before glue. A fraction of a degree matters here
Lets get clampy
On the lathe
No CNC here, just an old-school paper template
After sanding
After removing ends, final sanding, and first coat of finish
Cutting 1/4" dowels precisely requires a jig
Adjustment and assembly of the upper sections. The block with hole is used to sand the dowels accurately. Cyanoacrylate glue is used to minimize discoloration
Careful sanding creates slice
After first coat of finish
And second coat. An oil and varnish finish seems appropriate given the geometric complexity
The CNC router cuts the base out of a piece of marble floor tile
The finished object