Not exactly a Big Item,- But a Big Headache !!

rogerjenkins · 30th July 2012, 09:52 PM

Got a Big problem,- how to successfully make a SMALL Fiddly item without breakage !!

Item;- Wooden Brooches. Not sure where to put the problem,- so choose this forum !!
Order came from a Melbourne Calisthenics Club. I took one look and handed the item onto my inventive Woodturner mate at Murray Bridge, who is also having major problems with them. Dimension required is 50mm.long. They are a miniture version of Calisthenics, " Clubs," done in a Cross formation, with alternating Black & white painted bands along each club. The clip is simply a small brass Safety Pin araldited onto the back of each Wooden Brooch, ( the easy bit ). IF we can work out how to successfully make them, the Calisthenics Club is seeking to place an order of round 800 - 1,000 of the, " little critters. " They have already contacted numerous Chinese, etc., " specialized, Custom made product " manufacturers who never even bothered to get back to the club officials.
I am including a photo of the Wooden Brooch design required, along with an Actual Size Technical Drawing, so you will know what we are trying to successfully work out how to make. ( Mate over at Murray Bridge has a, " Success ratio," of one out of four attempts at present !! )
** Apparently the Calisthenics Club originally bought them from some old guy somewhere, but he's not around no more,- and took his production secret with him,-
just to be difficult !!! ( or should I say, " inconsiderate !! " )
Over to the Brains Department.
Roger

**Christos** · 30th July 2012, 10:21 PM

I have not turned enough wood to advise how this might be done consistency so I am really just taking a stab at it. Could this be done in two parts, the ball part and club part using mortise and tenon to join.

**Osbojo** · 30th July 2012, 10:50 PM

If they were in metal, I guess the quickest way would be on an NC lathe. Wouldn't take too long once the toolpath is set up. Might be worth running it past the metalworking forum to see if it's possible to turn timber in an NC lathe.

**tea lady** · 30th July 2012, 10:54 PM

Aren't they just like tiny finials?

Why the failures? Breaking the thin bit cos it has grain run out? What wood have you tried?

**_fly_** · 30th July 2012, 11:18 PM

Do they have to be wood?
Make one and make a mould to cast in resin, Good mould of the proper silicone. Not pen casting stuff.

**tea lady** · 31st July 2012, 07:01 PM

Originally Posted by _fly_

Do they have to be wood?
Make one and make a mould to cast in resin, Good mould of the proper silicone. Not pen casting stuff.

Personally, I think its only worthwhile casting something if it isn't turnable or cuttable, as casting doesn't really save time otherwise. These are just little finials. You just have to get the knack right.

**TTIT** · 31st July 2012, 09:51 PM

Go for it TL

I reckon would love to help you fill the order

**Reaper** · 31st July 2012, 10:58 PM

Originally Posted by tea lady

Personally, I think its only worthwhile casting something if it isn't turnable or cuttable, as casting doesn't really save time otherwise. These are just little finials. You just have to get the knack right.

im sure some older member would kill me for saying this but...

i would make a bunch of smaller tool (i have some made out of dentist tool) its really just a way for me to compensate for a lack of skill

but it works... haven't found a way to make a small gouge yet...

**Reaper** · 31st July 2012, 11:00 PM

by older i mean more experienced

**tea lady** · 31st July 2012, 11:11 PM

Originally Posted by Reaper

i would make a bunch of smaller tool (i have some made out of dentist tool) its really just a way for me to compensate for a lack of skill

but it works... haven't found a way to make a small gouge yet...

Dare I say it.... but it ain't the size of the tool that matters but how you use it. :

I thought they were after tips on what to do, not someone to do it instead. Which I could if they wanted.

rogerjenkins · 1st August 2012, 06:41 PM

My mate over at Murray Bridge, ( KBPensandmore ), is S-L-O-W-L-Y being, " driven up the wall, across the ceiling, and down the other side, " by these " critters. " His current success rate is approximately one-in-four, AND the Calisthenics Club in the Melbourne area only requires an order for about 800 - 1,000 of these Brooches, therefore IF you think you have a better idea on how to make them, - Please have a go, and show us, how it is done with success. Maybe you could end up with part of the supply contract, as the Club will gladly pay for the Brooches, and I am quite sure KBpensandmore won't complain, as I am certain your effort/s will save him being," slowly driven up the wall, across the ceiling, & down the other side. As the heading of this reply says, " C'on all you knowledgeable folk,- have a go if you want to !! "

'ave a good day, & happy wood-turning,
Roger

**smiife** · 1st August 2012, 07:42 PM

go for tea lady!!!!!!!!!
don't forget we want photos blow by blow

cheers smiife

**tea lady** · 1st August 2012, 11:25 PM

OK!

**fozz** · 2nd August 2012, 12:30 AM

well, come on come on, show us the progress, and pics as proof too, remember, no pics it didnt happen

**tea lady** · 2nd August 2012, 08:46 AM

Originally Posted by fozz

well, come on come on, show us the progress, and pics as proof too, remember, no pics it didnt happen

Patience grasshopper.

Thread: Not exactly a Big Item,- But a Big Headache !!

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Not exactly a Big Item,- But a Big Headache !!

C'on all you knowledgeable folk,- have a go if you want to

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