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RETIRED
24th Feb 2011, 05:41 PM
I was contacted by Jim Carroll who wanted some big gate posts to make a statement.

Perhaps he is opening a winery now?:D

After going through my pile of phone poles and logs we decided on an Ironbark pole that had been up since 1935.

The dimensions were 250mm diameter by 2900mm long.

The drawing.

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It must have been a post on a corner because it had that many nails in it you could start a foundry.

After cutting to length we bought them in and put them on trestles to denail them.

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The pole ID plate gives timber type and date of erecting.

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The next part is centering. We use a disc, a centre punch and a hammer.

This is then marked with a wax crayon.

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Using block and tackles we then position the blank in the lathe with the biggest (or heaviest end) at the head stock and lock it in.

This is checked and rechecked about 3 times.

Speed and direction of rotation is checked also.

You don't want one of these bouncing off your chest.

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When all this is done, the slings are released, the piece turned by hand and the tool rest put in place. We try to use a one piece rest as it makes getting flowing lines easier than if you have to move smaller rests all the time but we do use them. See later.

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When everything is set, anyone within the firing zone is cleared and the lathe started remotely on the right hand side.

Whilst the log is rotating I keep my hand on the switch to shut it down immediately should any thing happen.

If all is good it is switched off and all locks are checked again to make sure that nothing has vibrated loose.

The speed at starting is 320 RPM in this case. Sometimes we have to start at the lowest setting. 57 RPM.

I start to get the log round now by removing the waste.

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When the log is close enough to round the speed is increased to 420 RPM.

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This is the speed it will remain at until finished.

Once it is round I look for the narrowest point ABOVE where it will go in the ground.

I use the Ci1 rougher as a parting tool and get the log perfectly round at that point.

Note the reference point on rest in white. All measurements will be taken from this point. This is the bottom of the post.

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I then measure this with calipers and note the size. I write this on the tool rest with a white paint pencil.

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Using the calipers and the parting tool I mark out reference sizes about 600mm apart down the log.

The calipers are set about 5mm larger than finished size to allow for smoothing cuts and sanding.

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Once these are in place we "join the dots" or in this case the grooves to get the post down to size.

Once we have that done, the lathe is stopped and I run the calipers over the whole post marking high spots with a crayon.

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We start the lathe up again and take them out with smoothing cuts using a large gouge.

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This is the difference between a roughing cut on the left with a smoothing cut on the right.

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One parallel log ready to mark out.

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If we don't have actual dimensions to work to (it happens a lot) I use experience and the drawing to get the balance right on the post. You have to remember that a post looks totally different vertical than horizontal.

After I have penciled in the lines at the details I sometimes stand on the lathe or turn my head sideways to envisage what it will look like standing up.

I then mark the tool rest with that white marker and write what the detail is. It is easy to put a cove in where a bead should be. Disastrous is the best description.

That way you end up with 2 reference points after the 1st one.

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I then mark the post with a skew chisel. I do this for a couple of reasons. It gives a visual reference that something goes there and when you have to part in there is no tearout at the edges so keeping them sharp.

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If the post has enough bulk I will part out where the coves are going next. On smaller diameters I will do the beads first to keep the strength in the post until the last moment.

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I use a long and strong detail gouge (old style) for doing the coves.

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With the coves done I cut the beads next with a traditional spindle gouge ground to a thumb nail shape.

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With the coves and adjoining beads done I clean up the fillets with a skew.

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With those done I run the taper.

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Now I move up the post and do the top.

Where the bead meets the straight cylinder it is too tight to get a gouge or skew chisel in so we resort to something else.

We start the cut with a normal gouge but finish with a narrow detail gouge with a lady finger grind on it.

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Getting near the end now. You will note that I have not reduced the post in size any more than necessary at the head stock. The old posts that we turn can quite often have cracks that will allow the post to snap out of the drive spur.

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Again it is an anal clenching moment if that happens not to mention annoying.

If it looks like breaking we can put a steady in to support the post while we hasten slowly.

At about this point we sand the post starting with an angle grinder and in this case hand sanding to 150# as these are being painted.

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After sanding, the long rest is slid to one side and a small rest used to get in close to the final part. This is turned and sanded.

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The first one done.

Whist working we sharpen the chisels about every minute. The grinders are not switched off.

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Round 2

Next post in.

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Normally we put the completed post behind as a pattern and reference for turning the next so that we can get curves and details the same.

Because it is so big we have to have it overhead.

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And so it begins again.

Sorry about being so long.

Woodwould
24th Feb 2011, 11:14 PM
I was contacted by Jim Carroll who wanted some big gate posts to make a statement.

Tell Jim he'd be better off with an orator then.

Did TL get her jeans caught in the lathe again?

Fantastic work there . :thyel:

Claw Hama
24th Feb 2011, 11:32 PM
Great job (&TL), would love to make me one of those mini lathes. First I'll have to get a bigger shed:roll:. Great WIP.

Paul39
25th Feb 2011, 06:35 AM
,

Very nice tutorial, which also translates to those of us who do smaller work.

Tea Lady, please wear a mask when sanding. Fine dust in the lungs is not good for you.

I have not done this a few times - "oh just a quick sand, the exhaust fan is on", and paid with several days of coughing and occasional upper respiratory infection.

mkypenturner
25th Feb 2011, 07:03 AM
nice pics :2tsup:

Ozkaban
25th Feb 2011, 09:13 AM
Nice WIP :2tsup:

That's a hell of an intimidating lump hanging over the lathe second time around! How long did each post take?

Can we get some pics of them installed?

Cheers,
Dave

Sawdust Maker
25th Feb 2011, 09:34 AM
Thanks

I see you were given very detailed blueprints at the beginning

And I agree with Paul's comments on the mask

rsser
25th Feb 2011, 09:51 AM
Awesome work.

joevan
25th Feb 2011, 10:05 AM
Hello and TL,

Do we get to see those monsters tomorro? What input was there from Jim, with a bit of imagination he should have been able to do this sort of job on his "stubby".

BR Joevan.

Cliff Rogers
25th Feb 2011, 10:07 AM
io! What about a dust mask while sanding?????? :rolleyes:

Trust some bugger to pick on something. :D

RETIRED
25th Feb 2011, 11:02 AM
Tell Jim he'd be better off with an orator then. He does a good job on his own.:D

Did TL get her jeans caught in the lathe again? No the dust extractors are the cause of that.

Fantastic work there . :thyel:





Nice WIP :2tsup:

That's a hell of an intimidating lump hanging over the lathe second time around! How long did each post take?

Can we get some pics of them installed?

Cheers,
DaveAbout 2 1/2-3 hours. Jim will probably take some.


Thanks

I see you were given very detailed blueprints at the beginning

And I agree with Paul's comments on the maskThese are detailed compared to some we get.


Hello and TL,

Do we get to see those monsters tomorro? What input was there from Jim, with a bit of imagination he should have been able to do this sort of job on his "stubby".

BR Joevan.Yes Joe. The drawing.

RETIRED
25th Feb 2011, 11:05 AM
Thank you everyone for the comments.

Twins!!!:D

ticklingmedusa
25th Feb 2011, 12:57 PM
Cool !
Thanks for posting :2tsup:

Hors
25th Feb 2011, 02:29 PM
In a word

AWESOME !

Mulgabill
25th Feb 2011, 04:00 PM
Great work & TL:2tsup:
Is Jim taking them home on the roof rack??:q

rsser
25th Feb 2011, 04:17 PM
heheh .... these installations may have some unintended consequences.

Customers will turn into Jim's drive, eyes popping, and then come in and say "Love those posts. Give me a lathe that'll do them" :rolleyes:

dai sensei
25th Feb 2011, 10:13 PM
Well done :cool: and TL. Great WIP :2tsup:

A job that big is something most of us could only dream about. I'm one of the lucky ones to have seen a similar sized blank on 's lathe. Lathes speeds of 300-400 may seem slow to those of us with smaller lathes, but with this sized blanks, let me tell you it's scary :o:U:U

TTIT
25th Feb 2011, 10:31 PM
Better not show Con those posts - he might get ideas for the entrance to Camp Kanga and give you a project this year :o Great WIP :2tsup:

Cliff Rogers
25th Feb 2011, 10:37 PM
Better not show Con those posts - he might get ideas for the entrance to Camp Kanga and give you a project this year :o Great WIP :2tsup:
Hmmm.... all those bollards around the oval could use a bit of 'upsizing'. :think:

RETIRED
25th Feb 2011, 11:01 PM
May have to wait. We won't be at Prossy this year unfortunately.

tea lady
25th Feb 2011, 11:07 PM
Tea Lady, please wear a mask when sanding. Fine dust in the lungs is not good for you.

I have not done this a few times - "oh just a quick sand, the exhaust fan is on", and paid with several days of coughing and occasional upper respiratory infection.Its OK! Paul! I didn't inhale! :D

artme
26th Feb 2011, 08:50 AM
:o:o Now that's a real WIP!!!

Great stuphph you tow and thanks for posting.:2tsup::2tsup::2tsup:

tea lady
26th Feb 2011, 08:52 AM
:think: Maybe it should have been put in "Big stuff" ? :cool::D

brendan stemp
26th Feb 2011, 09:10 AM
Thanks or, after seeing that hood you wear, should I call you Sir Turnalot.:D Some incidentals were of interest to me. Apart from your 'hood' I liked your measuring systems; both on the tool rest and the ruler screwed to the wall. And I also like your sanding system; ie when all the fun bit is done hand it over to TL to sand. I wish I had one of those.:D

murray44
26th Feb 2011, 09:11 AM
Lovely work and a great WIP.

But they're going to be painted you say....:oo:

specialist
26th Feb 2011, 09:28 AM
Awsome

tea lady
26th Feb 2011, 09:48 AM
And I also like your sanding system; ie when all the fun bit is done hand it over to TL to sand. I wish I had one of those.:D:rolleyes::D and I even make tea! :p:D

martrix
26th Feb 2011, 10:03 AM
pretty cool . Industrial wood turning.

Ed Reiss
26th Feb 2011, 01:18 PM
Well ...now that the cols are done, you can get that mercedes finally:U

Sturdee
26th Feb 2011, 04:54 PM
Saw them today, they are indeed awesome.


Peter.

FenceFurniture
26th Feb 2011, 05:15 PM
:)(Bloody Hell! Some people make miniatures of things, and others......

Jeez , don't ever take up nude male sculptures willyer. You'd have to ask me down to model, and I can't afford the airfare (have to get three seats see).

It's unbelievable work! How big are the gates going to be? Therefore, how big is the car that goes through them? Or does Jim have six lane divided road (with toll) going up to the house? Does he accept Etags?

RETIRED
27th Feb 2011, 04:33 PM
Lovely work and a great WIP.

But they're going to be painted you say....:oo:After Jim saw the colour he may oil them.

powderpost
27th Feb 2011, 05:43 PM
Nice job lad. Just got home after driving through Cardwell. More than a few large old tea trees, and others, lying around waiting for some tlc.

Nice to see you wearing a face mask , not sure it would help if the job came adrift?????? :oo: :wink:

Jim

Grommett
27th Feb 2011, 06:08 PM
Saw them yesterday, even more impressive in real life. Beautiful figure, it would be a shame to paint them. Now does Jim have a stately manor to put behind them?

Jim Carroll
27th Feb 2011, 08:14 PM
We saw similar posts a while ago and decided we wanted turned posts for our driveway.

I can turn up to 12' long but no where near the diameter we wanted, weight has a big factor. Our fork lift will not get into our shed either.

So Who ya gonna call



Had a chat and drew up a bit of a drawing of what we wanted and left the rest up to ..

Put him under a bit of pressure to have them ready for the weekend as it would be a fair while before we can get back over to his place. Lots of shows coming up in the next couple of months.

We had originally thought of painting them but after seeing the color and feature of the Ironbark we have decided to oil them .

I will give Livos a call in the morning to confirm what they would reccomend for timber that is 75 years old, there was the copper plate still embeded in the post indicating 1935.

loaded them into the back of the ute this morning and with the rain on them it gave us a fair indication of what they will look like when oiled, very nice indeed.

Got them home ok but it continued to rain so did not get them set up.

As soon as we get a chance I will post some photos of what they look like in position.

No we dont quite have a home to match the posts, maybe one day whe we get a wink of George.

kudos to he has done a mighty fine job as you would expect.
It was also good for all the guys there yesterday to see something different.

ticklingmedusa
27th Feb 2011, 08:21 PM
Nice lines on them.
Excellent choice on the use of something that will show off the beauty of the wood.:2tsup:

NeilS
28th Feb 2011, 11:39 AM
Impressive, as usual, .

Love that long handled gouge!
.

issatree
28th Feb 2011, 03:20 PM
Hi ,
The Pole in the 3rd. & 4th. Photos tell me they were S.E.C. Poles, ( State Electricity Commission of Victoria.) They were also Octagonal, which that pole was.
It was what you might call a Dual Pole, as the P.M. G. ( Post Master General ) or Telecom were allowed to make use of the SEC Poles for their Wires as well.
So the Concaved Dark Disc would be Brass, & as you said all the info about the Pole.
It would have printed, S.E.C. Then most likely 40, meaning 40 ft in length, & seeing you said Iron Bark, it would have IB there as well.
Now the Brass Discs were from 00 which was 1900 ( very collectable ) to 58 / 1958, as they then changed them to Aluminum. The nailed round Aluminum Disc is most likely SEC as well.
I have a nice Collection of these Discs, as I would change them from Convex to Concave, & made many Ash Trays for the Smokers, as most times I could find their Birth Year on them.
I was never able to find a " 00 " Disc, but a few of the Linesman did. Believe or not, there are still some 1900 Poles still standing, & in good condition.
The Yellow Plate was the P.M.G's info plate.
As for all the nails, The SEC never used that many that I am aware of.

ravna
28th Feb 2011, 03:56 PM
Very impressive ....methinks you may have made a rod for your back...the punters will be lining up at the door.

Good to see you were able to match the age of the poles to Jim.

cheers

John M

Harry72
28th Feb 2011, 04:16 PM
I heard you had taken up pen turning ...

RETIRED
28th Feb 2011, 04:59 PM
I heard you had taken up pen turning ...
Yeah, right.:rolleyes::D

RETIRED
28th Feb 2011, 05:03 PM
Hi ,
The Pole in the 3rd. & 4th. Photos tell me they were S.E.C. Poles, ( State Electricity Commission of Victoria.) They were also Octagonal, which that pole was.
It was what you might call a Dual Pole, as the P.M. G. ( Post Master General ) or Telecom were allowed to make use of the SEC Poles for their Wires as well.
So the Concaved Dark Disc would be Brass, & as you said all the info about the Pole.
It would have printed, S.E.C. Then most likely 40, meaning 40 ft in length, & seeing you said Iron Bark, it would have IB there as well.
Now the Brass Discs were from 00 which was 1900 ( very collectable ) to 58 / 1958, as they then changed them to Aluminum. The nailed round Aluminum Disc is most likely SEC as well.
I have a nice Collection of these Discs, as I would change them from Convex to Concave, & made many Ash Trays for the Smokers, as most times I could find their Birth Year on them.
I was never able to find a " 00 " Disc, but a few of the Linesman did. Believe or not, there are still some 1900 Poles still standing, & in good condition.
The Yellow Plate was the P.M.G's info plate.
As for all the nails, The SEC never used that many that I am aware of.Thanks Lewis. The nails were from people nailing signs on them.

The SEC used coach screws which make a nice job of blunting the tool (read chip) resulting in much profanity and wasting a lot of time.:wink::D

Sawdust Maker
28th Feb 2011, 07:47 PM
a man who listens to opera using profanity :o
what's the world coming to :roll:

issatree
28th Feb 2011, 08:21 PM
Hi again,
Yes, I was going to mention that some people attach signs to Power Poles.
As for the Coach Bolts, there was always the Lazy Liney who would not Dip the C/B
in the Joggle Grease, & would hammer it in, & when we went to remove them, years later, would most likely screw the head off, because they went rusty. Did the same to our Chain Saws.

RETIRED
28th Feb 2011, 08:46 PM
a man who listens to opera using profanity :o
what's the world coming to :roll:But only in Italian or German. :roflmao:

Sawdust Maker
28th Feb 2011, 09:01 PM
touche

hmm have been listening to the heavy rock in the shed lately (turned up of course)
Wonder what the neighbour will think of Der Ring des Nibelungen? :U Might try her out on Die Walküre tomorrow :2tsup:
Might need new speakers :doh:

rsser
28th Feb 2011, 09:14 PM
Wonder what the neighbour will think of Der Ring des Nibelungen?

That some kind of captive ring Nick?

nz_carver
28th Feb 2011, 09:24 PM
Hey what did one woodturner say to the other woodturner??
can you turn me some gate posts??

Ok says to Jim:U:q

Hey Jim your not one of them guys that rings NRMA to change a flat tyer are you??

sorry dont take it wrong mate after the week I have had I have not stopped lol at the posts:;

Jim Carroll
28th Feb 2011, 10:09 PM
Hey Jim your not one of them guys that rings NRMA to change a flat tyer are you??

:;

If you have seen the size of the tyres on my ute you would call the RACV :oo:

Cliff Rogers
28th Feb 2011, 11:13 PM
a man who listens to opera using profanity :o
what's the world coming to :roll:
Better than if he listened to profanity & sung opera.

Ozkaban
1st Mar 2011, 08:16 AM
If you have seen the size of the tyres on my ute you would call the RACV :oo:

You could always call these nutters:
YouTube - Crazy Saudi

GoGuppy
1st Mar 2011, 12:41 PM
You could always call these nutters

They've probably got 's lathe on the other side of the truck :D

tea lady
4th Mar 2011, 12:04 PM
Better than if he listened to profanity & sung opera.:C Yes!



:D

HSS
4th Mar 2011, 08:38 PM
Just wondering what horsepower your lathe is and how much the blank weighed??

Cheers.

RETIRED
6th Mar 2011, 08:35 PM
3 HP and I estimate when I started 500 kilos.

cookie48
6th Mar 2011, 08:42 PM
and when you finished???????????

RETIRED
6th Mar 2011, 09:00 PM
Probably about 250-300 Kilos. Needed 2 people to stand it up.

Ask Jim.:D

Jim Carroll
6th Mar 2011, 09:34 PM
Probably about 250-300 Kilos. Needed 2 people to stand it up.

Ask Jim.:D

I thought gravity would help when pushing them of the ute but it needed me and young Lee to stand them upright.

cookie48
6th Mar 2011, 10:33 PM
Bloody big ute. Maybe you should come out to Elizabeth S.A. and teach some of the hefers here how to loose 250kg that easily

HSS
6th Mar 2011, 10:58 PM
Impressive . I was worried about my 3HP lathe possibly being under powered with large stuff. I haven't tried it out yet.

Jim Carroll
21st Mar 2011, 03:51 PM
Well here they are in the ground.

It was an easier job than expected as the ground is very easy to dig in our are and going down the 600mm was no problem at all.

Rolled the post ont the tynes of the forklift then postioned over the hole and let gravity do the rest.
Then it was just fill and pack fill and pack till we had them jammed in neatly.

Dont think they will go too far.
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TTIT
21st Mar 2011, 03:57 PM
Very cool :2tsup: . . . .but a coat of oil wouldn't go astray :; (sump oil would do!)

Sawdust Maker
21st Mar 2011, 03:59 PM
Jim

Nice

You'll have to get a couple of fancy gates now as IMHO those there look a little shabby with those speccy posts

tea lady
21st Mar 2011, 04:10 PM
:C They look weird going in that direction! :doh:

very nice though! :cool: We'll be able to find your joint now! :2tsup:

ticklingmedusa
21st Mar 2011, 05:16 PM
:2tsup:

Jim Carroll
21st Mar 2011, 07:35 PM
Very cool :2tsup: . . . .but a coat of oil wouldn't go astray :; (sump oil would do!)

Dont know about up your way vern but it is now illegal to use sump oil on fences etc.

Got a couple of coats of Kunos decking oil on them tonite and they look really good.
Brings the red out in them.:2tsup:

Jim Carroll
21st Mar 2011, 07:36 PM
Jim

Nice

You'll have to get a couple of fancy gates now as IMHO those there look a little shabby with those speccy posts

Very true may have to work on that.

springwater
21st Mar 2011, 07:42 PM
:2tsup: Great improvement, they sort of remind me of the old post office boxes that once stood like sentinels, 'cept they were bright red and fatter...:-