The clock is more or less finished at this point. I need to make a pass with 400 grit sandpaper and apply the finish. Once that is on and dried I will have the final post up, which should be by the end of this week.

The first photo shows how the miters and splines go together. End grain does not glue well. The spline helps beef it up by giving it more surface area and makes it so it has to break before the glue line does. The other shows how it will look once glued.

I have a mortise machine that makes getting square holes fast and accurate. In this case I had to do multiple holes that went all the way through the board. Because the ends of the gear were not perfectly square and even flared out in spots, I had to do some hand shaping with a file to make it so the gear set right.

After sketching out ideas and stewing over the whole thing I decided the best way to make it so the time piece could be rotated was to go low tech. The time piece fits very snugly into the gear to the point where it can’t be taken out with your hands. So, the idea is that you press the time piece into the front of the gear in the desired position and then push the wood back in on the other side. The wood back like the time piece fits tight enough that it can’t be removed with your hands. It therefore has a notch cut out for a flat head screwdriver to pry the back off and allow the time piece to be pushed out.

After clamping everything dry (without glue) to make sure it would work right I taped any area where glue could possibly squeeze out. This makes removing extra glue very easy and is a must. It will save you time and sanity. And in my case with the gear set inside I had already sanded the wood to a 400 grit and didn’t want to sand it again risking hitting the gear.

I have encountered a problem with the bronze caps on the end of the splined miters. Unfortunately, I have discovered that I don’t really have the tools at this time to work the bronze down that small. I am trying to make the bronze work, but I have started working on alternatives for the sake of my fingers. I will show you whatever I do. The cap is purely for aesthetics and won’t alter the strength of the joint.

About sean favero

Designer with furniture as a medium. Seeking to create long lasting good quality designs.
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