Stave Vessel Design & ConstructionTom KenyonMay 2012

*The Art of Segmented Wood TurningBy Malcolm Tibbetts10 is too Tall - looking for about 66/4 wood required for staves - prefer 4/4

*First Prototype

Symmetrically scaled plan to 6 high Simplified construction Eliminated veneer layers Eliminated multi layers splines

*Revised DesignPrototype too roundTop out of proportion to the bodyCenter divider too thickCreated lip for top/body jointSecond prototype looked good

*PartsNeckTopSeparatorSplinesStavesBottom

*Stave Cutting Jig Based on Replaceable Throat Sled My Friend!

*Stave Cutting JigFirst Ten Vessels

*Dedicated Segment Cutting SledDesigned to accommodate Bridge City Tools Angle MasterLarge rear fence openingRemovable segment slide

*Vessel Holding FixtureUsed for;Initial glue up of stavesInitial turning of the baseFinal turning of the baseDesign from PBS TV show and Malcolm Tibbetts bookDuct tape help donuts slide

*Ring Sanding JigShown previously in Show-n-TellDescriptive article posted on Segmentedwoodturners.org

*TemplatesTemplates cut out of 1/16 plastic on the laserOutside only one that proved useful

*ProductionProduction of 20 broken into three groups - 10, 5, and 5Manageable number of partsDoable task - not overwhelmingAssessed mix after each groupWood combinations that worked or didnt workAppropriate mixAvailable material

Timeline (best recollection)Design started late Sep, done by third week of NovLots of time finding material (tops) and making prototypes, jigs, and templatesFour weeks to the first prototypeOne to two days to prepare material - almost independent of number of vesselsTwo vessels going simultaneouslyAbout a day for each

*Parts Preparation

*Parts Assembly and Glue up

*Top Top opening drilled after finishing - fits tailstock plug - helps alignment during glue upInside finished with shellac

*Base/BottomLots spinning ! Slow is OKWatch out for those bolt ends!Inside bottom base cut to blend in with bottom plug, also gives reference for turning inside

*Turning Base Inside & OutsideTrick is getting a tight fit with topInside finished with shellac

*Finishing the VesselLast step is to make plug to center vessels top on the jig

*All Done ! Used General Finishes sealer and oil/urethaneBuffed with brown paper sack after a week

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