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A completely useless object


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The CAD model

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Cut the segments using a cutting jig on the miter saw

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Sand with a sanding jig

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This ensures they are all the same size. A disk works better than a belt for this since it's flatter and more rigid

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Glue the segments. Soft steel wire is used for clamping. Note the precision digital angle measuring tool

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Mount the piece in the CNC router to finish the center hole

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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

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A jig was made on the CNC router to hold the slices for drum sanding

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The same jig was also used to hold the top pieces in place for drilling

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The CNC cut the center hole a bit undersized. Hand fit using the spindle sander

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Put tape on the back of a piece of 1/4 MDF

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Use the CNC to cut spacers

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The pieces are held by the vacuum fixture and the tape

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The finished spacers

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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

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Assemble the pieces on the shaft. Numbers help keep the pieces in order

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The finished glue-up. The top 3 sections are not glued

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The top sections are not glued. They are attached with a screw, washers and a clamping disk

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The complete stack

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The top clamping disk fits the lathe chuck perfectly

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On the lathe, ready for turning

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Basic shape finished

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Now, cut the grooves

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This is a tricky and delicate operation. The large pieces on a thin shaft cause it to chatter a bit when cut

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It would be really easy to ruin it now. So go really slow and careful

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After sanding. The three top pieces are separated for the next operation

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The ball cutout is a 3 axis, inside sphere. Test it first on MDF

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Now, route the real thing

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The finished cutout

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Clamp the segments for the ball

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Sand with a jig

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Final hand sand before glue. A fraction of a degree matters here

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Lets get clampy

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On the lathe

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No CNC here, just an old-school paper template

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After sanding

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After removing ends, final sanding, and first coat of finish

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Cutting 1/4" dowels precisely requires a jig

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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

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Careful sanding creates slice

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After first coat of finish

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And second coat. An oil and varnish finish seems appropriate given the geometric complexity

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The CNC router cuts the base out of a piece of marble floor tile

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The finished object