The Rings - Phase III
- Glue And A Big Mess?
Well, here is Part III
of this aggrevation and misery and ways to not ruin, but devastate my aching
back and knees.
We need to cut rings from
1/4" Baltic Birch and prep everything prior to gluing.
The effect we want when
done is this.
The Top Ring, (3) layers
of 3/4" ply, will attach to The Domer and keep it round and the base
of The Domer flat. It will have a 1" groove milled into it for the wheels
to ride in.
The Middle Ring is thin
and its sole purpose is to hold the wheels in a slot, vertical and in place
between the Top and Bottom Rings.
The Bottom Ring is (2)
layers of 3/4" ply and will support the Domer and tie the (12) wall panels
into a cohesive structure. It will have a 1" groove milled into it for
the wheels to ride in.
Half done with the first
sheet, we attach it to a fresh 4x8' sheet of ply.
All done with the first
panel. The cut into the corner will not matter as it will trim square.
A pile of segments.
Like, Duuh, if the holes
are getting sloppy, add some more wood and use two bits instead of one to
make the task easier.
The 3/4" is all done
(5) Stacks of segments.
Now we need to mark the
other end and we will make a jig.
This will index the end
This will support the
And, we mark the opposite
end. This will give us a circumfrence for this segment of 50.5".
The segments for the Middle
and Lower Rings will be 50" exactly.
I played with the groove
and wheels. This is 5/8" deep and is almost too deep. I will guage this
further as I actually make the grooves in the rings.
We place screws in the
center and outward every 8".
I made marks 1/2"
in from the end. This feels about right.
We make little dots for
the screws to be located at.
Qstn. How do we easily
make the screws tangent to the edge?
Easy. Use the end of a
finished segment and align both pieces with care. The ends are tangent to
The screws in place. They
extend a bit on the bottom side. By carefully aligning both pieces and using
a rubber hammer, we will locate where all (14) screws go for each segment.
Btw, the jig was also
used for the Middle and Bottom Layer 3/4" ply as well. Hardly any differnece
which was surprising.
The marks after bashing
The Bashing Equipment.
Now to drill 14 x 6 x
4 = 336 holes. And do it again for the 1/4" ply segments.
By drilling into a sacrifice
board, the bottom of the holes are not all chipped up and do not require any
Once again, all done with
Annie, in a familiar pose.
She is actually looking
for me. I must be making too much noise for her naps.
Setup for the 1/4"
ply. I placed a segment under the sheet at the end of the table for support
and needed to weight down this end so it did not fall out of the shallow hole.
Here is the business end.
These segments were real
easy to trim out. One pass.
More Tools of Torture.
No wonder the segments
had gaps and issues. Way too much variance. I marked and trimmed all of them.
I did not have this problem with the 3/4" pieces.
The Bottom Ring glued
I use lotsa glue and coat
each surface with a roller. Gotta work fast!
All done ready for a wash.
I only wiped the glue
of the upper and lower surfaces. Did not slob too much water here and there.
Big, is it not?
All the screws, nice and
Wow! Lotsa hole here.
If your holes look like
this, the chips have to be sanded off.
Here is how I pulled the
segments into circular fashion. These are 2/2's and the strap goes around
them. Do not tighten too much so the whole thing flies apart, but I did snug
it up pretty well. Using lotsa glue means the pieces can be adjusted and aligned
with each other fairly easily.
This really makes it easy
to make a circular piece round - not egg-shaped.
A close up
Two done and drying.
For the Middle Ring, we
need to drill a 1/4" hole for the axle for the wheels. A drill press,
even a modest one, works pretty well for this. I placed (15) not (16) wheels
every 20" apart. Making certain not to place an axle where the screws
may run thru the hole.
(16) wheels would have
made the 20" 18 3/4". 20" was just easier to calculate and
The homemade jig and clamps.
Three rings, all done
and in bed for the night.
So, how did I do.
The Top Ring is 96 1/2"
on one side and 96 3/8" on the other.
The Middle Ring is 95
1/8" on one side and 95 3/8" on the other. This ring was really
hard to handle and get right.
The Bottom Ring is 95
1/2" no matter where I check it.
Next, will be to grind
off the glue on the edges, even up any segments slightly out of place, round
the edges with the router, cut the slots for the wheels in the Middle Segment
and, figure out How In This World to make two tracks easily and accurately.
(To Be Continued)