Fluting With the FESTOOL 1400

[Bob Swenson]

First a little gloat. I helped a lady make room in her garage for her husband’s new Harley by removing this Delta Rockwell Lathe. It came with a three-jaw chuck; a bucket of Tools and assorted tool rests. All for $250
1 gloat.JPG

To make the columns I glued 12 pieces of mahogany together (precision cut on the Sawstop) and rolled them up with Duck tape, clamping them with stainless steel auto hose clamps linked together.
2 boards.JPG4 clamping.JPG3 Roll.JPG

Next I bridged both ends with mahogany pieces and marked the centers. On one end I drilled and inserted a one-inch dowel to fit into the three-jaw chuck.
5 dowel.JPG

[Bob Swenson]

The jig was clamped to the lathe and the Festool rail and the Festool 1400 router were attached.
Using the homemade pointer I lined up the jig on a seam at both ends.
6 jig & R.JPG

7 line up.JPG

8 complete jig.JPG

[Bob Swenson]

Running the lathe I rounded the column in two passes using a ¾” bull nose bit, I then sanded them smooth with a Festool 150 /3 EQ sander. NO DUST!
The flutes were cut with the same bull nose bit, lining up the first cut with the edge of the
first seam so as not to cut into a glue joint. Because the lathe index has only 60 index holes and is not divisible buy 24, I had to cut 12 flutes and readjust to cut the next
12. I lined up the first flute exactly in-between two of the already cut flutes with the pointer tool and the Festool micro adjuster and cut 12 more. The adjustable stops on the guide rail made it easy to accurately start and stop the flutes. I marked the Jig so I could see the end to avoid burn marks.
1111 end mark.JPG10 Micro.JPG
Next I glued up these hex pieces using a Merle adjustable corner clamp, band sawed them round and finished them on the lathe.

12 Merle clamp.JPG

[Bob Swenson]

The base carvings were done using the Carvewright.
13 14 15 16 13 base carving.JPG

14 full column.JPG

15 full column 2.JPG
Then off to the finish Carpenter who always complains that I am always late!!

As Norm would say “ Now over to my Leigh Dovetail Jig to make drawers.”

Bob

[Jay Brewer]

Absolutely beautiful work Bob, great job

[Jim Becker]

Great job, Bob! This is a great illustration on how to re-purpose tools to work together towards an end. Combining the guided Festool router with the lathe was a wonderful way to accomplish these very nice columns!

[Richard Wolf]

Great job Bob.

Richard

[Dan Forman]

Very classy looking columns. Now that you're done with the lathe, can I have it?

Dan

[Jim Hager]

Super work, I've always wanted to do something like that but never had anyone call for it. I'd have to buy a carvewright first though.

[lou sansone]

nice job on the column. I have used similar jigs for them as well. I had not thought to use the router and a pointed bit to line things up. I have made a seperate jig to do that, but your method is even better. thanks for the info
lou

[Bob Swenson]

Jim, Now that I have the jig I am going to make a plant pedestal and perhaps
A couple of lamps. With two more stops on the rail you can make two flutes in one pass.
Cut the column in half and voila, a pair of lamps.
Of course all this is after the kayak, the flamenco guitar, the C5A ¼ scale WWI plane.
The new kitchen, and restoring my 1860 Steinway, and, and, and!!!

Lou, I did not make the pointer long enough; I should have made it the length of the router bit.
I am going to make a ¼ inch one. Could be useful on the drill press
Bob

[Jim Becker]

You can leave the 1860 Steinway off here once our addition is built and I'll be happy to use it without the restoration... No charge for "storage"...

[Greg Mann]

I Of course all this is after the kayak,....

Bob

Bob, A year ago I asked Per how Bob was doing on the kayak! At the time I was just pulling his chain a little. Now I find out he really did give you the job. I guess it doesn't matter how old they get, they are still your kids, eh?

Greg

[Bob Swenson]

Jim; would you really store my 1860 Steinway carved rosewood grand with dolphin Pedals, fretted music stand, tiered moldings and fine ivory and ebony keys -for nothing.
What a guy!!


This was the second oldest Grand piano in the old Steinway contest. Some old bitty in Texas beat me. The prize was a $30,000 restoration by Steinway, now it’s a do it yourself

[Bob Swenson]

Greg--- I get no respect