TS55 pattern sawing

[Mike_Chrest]

Here's a technique I haven't seen mentioned much on the web, but it is handy if you want to make staves for a barrel,hot tub,column, or planks for a wooden boat.

Turn your garage into the Parthenon ;D, Replace those rotten columns on the front porch.

I used to do this with a worm drive saw but the TS55 works fine and the dust collection is made for this job.

What I wanted to end up with is four of these.

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10ft high,18" diameter  at bottom, straight for 30", tapering to 14" diameter at top.

 

[Mike_Chrest]

Here's the jig for cutting the staves.

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It's made of MDF. The pattern is screwed down on the left and the material is clamped on the right.

Since these parts aren't symmetrical it would be better if I made the jig wide enough to clamp the material on either side of the pattern. Then you could cut one side, move the part to the other side of the pattern, and finish the stave (I did all the right hand cuts first, repositioned the pattern on the jig, cut a second positioning kerf,then did the left hand cuts).

If your parts are symmetrical this jig is fine. Cut one side, flip the stave end for end,cut second side.

 

[Eli]

That looks cool. What are the final taper dimensions/column dimensions?

 

[Mike_Chrest]

I added a strip of oak flooring to the bottom of the TS55 to act as a guide fence. You could use the parallel stop also.

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[Mike_Chrest]

Hi Eli,

What are the final taper dimensions/column dimensions?

10ft high,18" diameter  at bottom, straight for 30", tapering to 14" diameter at top.

The staves are 3 1/2" wide at the bottom and 2 3/4" at the top.

Mike

Don't know what that is in metric  ;D

 

[Mike_Chrest]

The pattern & material sit on the jig with the inside up.

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I ran a curf in the MDF before clamping the first stave so I could position the material with the correct off-set for the taper.

 

[Mike_Chrest]

The saw rides on the pattern and the splinter guard rides on the material.

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I needed 16 staves per column x 4 columns =  64 staves  :-\

Bevel angle was 11.25 degrees

 

[Eli]

Hi Eli,

What are the final taper dimensions/column dimensions?

10ft high,18" diameter  at bottom, straight for 30", tapering to 14" diameter at top.

The staves are 3 1/2" wide at the bottom and 2 3/4" at the top.

Mike

Don't know what that is in metric  ;D

Sorry, I see that at the bottom of your post now. What's the inside edge angle? Only a few degrees? Looks like a double dado down the bottom? Did you set that up before glue-up or rotate the column somehow?

I'm all questions because I love it. 

I keep thinking I'd like to try a drum out of Aus hardwood, I have an Aunt that dates an African drummer. This would translate well. Thanks!
E

 

[brandon.nickel]

Mike,

Did you have to make a test cut (or cuts) and tweak your angles?  If not, how are your miters fitting using the built-in scale?

 

[Mike_Chrest]

I used the Panther blade which was very fast but on the rough side. Might try a different blade next time. Cleaned up the rough spots with a block plane.

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Cyclone saved me lots of bags on this job

 

[Mike_Chrest]

Eli,

I'd like to try a drum out of Aus hardwood

Yup this would work. You might have to reinforce the inside. The grooves were cut by hand with a chisel and shoulder plane when the columns were in two halves. After glue up around the Lally posts I finished em up.

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The grooves get bronze bands.

 

[Mike_Chrest]

Brandon,
 

Did you have to make a test cut (or cuts)

Yup, I took some scrap and made a long part, then cut it into 1" lengths and arranged them in a circle to see if the joints would close. The scale on the saw is pretty accurate. It is hard to see 1/4 degree though.
Mike