The Construction of Vertical Evolution Nigel Howe

The Thought Process June 2006 July 2008 June 2006

Cross Section Drawing with Cutting List

Design Issue

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

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

Flat, Soon to become round

Cutting the planks into 1 ½” planks for segmenting

Running the strips through the thickness planer

Cutting segments on the sled

Hand sanding the glue surface

Five sets of segments ready for the glue table

Cutting the maple strips

Hand sanding the maple strips

A segmented ring dry fitted inside a hose clamp

The segments are aligned as the clamp is tightened

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

The hose clamp is removed and glue is applied

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

The first ring glued and set aside to dry

A large diameter ring is dry fitted to check the joints

The light test is done large or small

The segments for the 3 top rings were cut oversize, then maple strips were glued to the side of 12 segments, the other 12 are left plain.

All 24 segments are then cut lengthwise. The eraser on the end of an unsharpened pencil make a great non-slip push stick.

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

All 24 segments cut and lined up

The middle strips have traded places

Ready for gluing

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

The reassembled segment is then cut to size

All 24 segments glued to make a complete ring

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

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

Mounted and ready to be flattened

½” bowl gouge makes the first cut

Light cuts with a square scrapper

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

Sanding the flattened surface

Checking the ring for flatness using a straightedge and a flashlight

One of the larger diameter rings being flattened

All 63 rings flattened

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

Another clamping method.

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

Another use for steel flanges and blinds

15” diameter faceplate to be glued onto section #1

15” diameter faceplate being glued to the top of section # 1

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

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

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

Shaped and sanded. Ready for the next step.

A view of the top of section # 1

The bottom half of section # 1 has been added

Shaping the inside of the bottom of section # 1

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

Front View

Starting to turn the top and inside of section # 1

Shaping section #1 which includes ring 19

Turning and sanding of section #1 complete

The outside of section #2 has been turned.

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

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

Section #2 turned and sanded

Section #3 ready for shaping and sanding

Section #3 in the donut chuck for inside turning

Support columns were added to the base to counter flex

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

Section #3 turned and sanded

All 3 sections in the finish room

Tape is placed below the glue joint

Final assembly begins

Section #3 glued in place

On the lathe ready to sand the internal glue joints

All sections together turned and sanded

125 hours of construction 40 board feet of wood ½ gallon of glue 1 Box of band aids 62 rings 1656 pieces of mahogany 828 pieces of maple 2484 total pieces of wood Not one “Nigel get out of the shop and come in the house” $300 total material cost 3 sleepless nights

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