Wooden Spheres

A commission to produce 60 Baltic Birch spheres of varying size.

See the finished product here.

01 – The sheets were cut into strips and glued up.

02 – Rough blanks of different size.

03 – The corners are cut off on the table saw to save time.

04 – The blanks are cut over-sized.

05 – A tapered foot is turned between centers and some material trimmed in the bandsaw.

06 – The blank secured in a chuck and the router jig set-up and ready to go.

07 – The cutting process

08 – The jig eventually bumps into the headstock.

09 – The spheres quickly begins to appear.

10 –The blanks are reversed and held in a cup-chuck with a single screw.

11 – The cutting process begins again from the other end.

12 – Matching up the curves.

13 - The spheres begin to appear.

14 – The jig is adjusted for the smallest diameter.

15 – Cutting the sphere.

16 – The cuts are lining up nicely.

17 – All the spheres have been cut.

18 – Sanding begins with the sphere held between two cup-chucks.

19 – The sphere is re-positioned often. I now use a vacuum chuck for sanding.

20 – the spheres with a coat of finish.