The Construction of The Construction of Vertical Evolution Vertical Evolution

Nigel HoweNigel Howe

The Thought ProcessThe Thought Process

June 2006

July 2008

June 2006

Cross Section Drawing with Cross Section Drawing with Cutting ListCutting List

Design IssueDesign Issue

A cross section drawing showing a A cross section drawing showing a curve made using regular segmented curve made using regular segmented

ringsrings

This drawing shows the changes to This drawing shows the changes to ring 19 to overcome the “slab” ring 19 to overcome the “slab”

problem.problem.

Flat, Soon Flat, Soon to to

become become roundround

Cutting the Cutting the planks into 1 planks into 1 ½” planks for ½” planks for segmentingsegmenting

Running Running the strips the strips through through

the the thickness thickness

planerplaner

Cutting segments on the Cutting segments on the sledsled

Hand sanding the glue Hand sanding the glue surfacesurface

Five sets of segments ready for Five sets of segments ready for the glue tablethe glue table

Cutting the Cutting the maple maple stripsstrips

Hand sanding the maple Hand sanding the maple stripsstrips

A segmented ring dry fitted A segmented ring dry fitted inside a hose clampinside a hose clamp

The segments are aligned as The segments are aligned as the clamp is tightenedthe clamp is tightened

Each ring is held up to a light Each ring is held up to a light to check that all joints are tightto check that all joints are tight

The hose clamp is removed The hose clamp is removed and glue is appliedand glue is applied

Placed on wax paper the ring is glued Placed on wax paper the ring is glued and realigned as the hose clamp is and realigned as the hose clamp is

tightenedtightened

The first ring glued and set aside to The first ring glued and set aside to drydry

A large diameter ring is dry fitted to A large diameter ring is dry fitted to check the jointscheck the joints

The light test is done large or smallThe light test is done large or small

The segments for the 3 top rings were cut oversize, The segments for the 3 top rings were cut oversize, then maple strips were glued to the side of 12 then maple strips were glued to the side of 12

segments, the other 12 are left plain. segments, the other 12 are left plain.

All 24 segments are then cut lengthwise. The All 24 segments are then cut lengthwise. The eraser on the end of an unsharpened pencil eraser on the end of an unsharpened pencil

make a great non-slip push stick.make a great non-slip push stick.

All 24 segments of a top ring. 12 with All 24 segments of a top ring. 12 with maple, 12 plain. 2 have already been maple, 12 plain. 2 have already been

cut.cut.

All 24 segments cut and lined upAll 24 segments cut and lined up

The middle strips have traded placesThe middle strips have traded places

Ready for gluingReady for gluing

Glue is applied. A straight edge is used Glue is applied. A straight edge is used on the maple edge to insure on the maple edge to insure

alignment.alignment.

The reassembled segment is then cut The reassembled segment is then cut to sizeto size

All 24 segments glued to make a All 24 segments glued to make a complete ringcomplete ring

All 63 rings glued! Next step, flatten All 63 rings glued! Next step, flatten both sides!both sides!

Hot melt glue is used to hold the ring Hot melt glue is used to hold the ring to an MDF face plate for flatteningto an MDF face plate for flattening

Mounted and ready to be Mounted and ready to be flattenedflattened

½” bowl gouge makes the first ½” bowl gouge makes the first cutcut

Light cuts with a square Light cuts with a square scrapperscrapper

Close up of scrapper cut. Close up of scrapper cut. Oh, look! Oh, look! It’s ring 13. Unlucky for someIt’s ring 13. Unlucky for some

Sanding the flattened Sanding the flattened surfacesurface

Checking the ring for flatness Checking the ring for flatness using a straightedge and a using a straightedge and a

flashlightflashlight

One of the larger diameter One of the larger diameter rings being flattenedrings being flattened

All 63 rings flattenedAll 63 rings flattened

Gluing the rings together begins. Gluing the rings together begins. You can never have to many You can never have to many

clamps!clamps!

Another Another clamping clamping method.method.

When all the clamps are being When all the clamps are being used , Improvise !!!used , Improvise !!!

Another use for steel flanges Another use for steel flanges and blindsand blinds

15” diameter faceplate to be 15” diameter faceplate to be glued onto section #1glued onto section #1

15” 15” diameter diameter faceplate faceplate

being glued being glued to the top to the top of section of section

# 1# 1

The top ½ of section 1 is mounted on The top ½ of section 1 is mounted on the lathe ready to start turningthe lathe ready to start turning

Starting to shape the underside of Starting to shape the underside of section #1. Photo taken without a section #1. Photo taken without a

flash.flash.

Starting to shape the underside of Starting to shape the underside of section #1. Photo taken with a flash.section #1. Photo taken with a flash.

Shaped and sanded. Ready for the Shaped and sanded. Ready for the

next step.next step.

A view of the top of section A view of the top of section # 1# 1

The bottom half of section # 1 The bottom half of section # 1 has been addedhas been added

Shaping the inside of the Shaping the inside of the bottom of section # 1bottom of section # 1

Section #1 has been fit to a custom built Section #1 has been fit to a custom built donut chuck, ready to finish turn the top and donut chuck, ready to finish turn the top and

inside.inside.

Front ViewFront View

Starting to turn the top and inside of section Starting to turn the top and inside of section # 1# 1

Shaping section #1 which includes ring Shaping section #1 which includes ring 1919

Turning and sanding of section #1 Turning and sanding of section #1 completecomplete

The outside of section #2 has been The outside of section #2 has been turned.turned.

Modifying the donut chuck for use on Modifying the donut chuck for use on sections #2 and #3sections #2 and #3

Section #2 clamped in place, ready to Section #2 clamped in place, ready to turn the inside.turn the inside.

Section #2 turned and Section #2 turned and sandedsanded

Section #3 ready for shaping and Section #3 ready for shaping and sandingsanding

Section #3 in the donut chuck for Section #3 in the donut chuck for inside turning inside turning

Support columns were added to the Support columns were added to the base to counter flexbase to counter flex

Sanding deep in section #3 with a Sanding deep in section #3 with a broomstick with sandpaper taped on the endbroomstick with sandpaper taped on the end

Section #3 turned and Section #3 turned and sandedsanded

All 3 sections in the finish All 3 sections in the finish roomroom

Tape is placed below the glue jointTape is placed below the glue joint

Final assembly beginsFinal assembly begins

Section #3 glued in placeSection #3 glued in place

On the lathe ready to sand the internal glue On the lathe ready to sand the internal glue jointsjoints

All sections together turned and All sections together turned and sandedsanded

125 hours of construction125 hours of construction 40 board feet of wood40 board feet of wood ½ gallon of glue½ gallon of glue 1 Box of band aids1 Box of band aids 62 rings62 rings 1656 pieces of mahogany1656 pieces of mahogany 828 pieces of maple828 pieces of maple 2484 total pieces of wood2484 total pieces of wood Not one “Nigel get out of the shop and come in Not one “Nigel get out of the shop and come in

the house”the house” $300 total material cost$300 total material cost 3 sleepless nights3 sleepless nights

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