Creative Woodworks & crafts 2000-01, страница 30

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line of the eyeball right from the pattern. Repeat using the mouth, eyelids, and assembled ring of rays as templates.

Cut out the face

Cut out all parts of the face. Remove the scrap pieces and fit the mouth, nose, eyelids, and rays. Remove the tape in preparation to shape and contour each piece.

Shaping and contouring

A key to shaping is to first identify and start with the lowest or deepest pieces viewed from the front of the project. In this project, the face is the lowest piece and the first to be shaped. Sand and smooth the cut edges to give the face a gentle rounded shape.

Use the shaped face as a guide to mark the rays, mouth, nose, and eyelids for shaping. This line will indicate where the shaping and contouring should stop.

The mouth, eyelids, and nose are shaped by sanding to the desired natural looking contours. The bridge of the nose should be kept wide and flat where the clock shaft will be bored and installed.

Particular attention is needed to keep the finished piece symmetrical, with the appearance similar from side to side. The sun rays are great fun to contour because of the deep relief (see Fig. 6). After checking the overall appearance of all pieces, smooth sand them.

Assemble the face

To prepare the face assembly, place the face on wax paper, then glue and pin in the nose, mouth, and eyelids. Set aside to dry.

If kit eyes are used, follow supplied instructions. If you choose to make your own eyes, refer to the accompanying sidebar.

Glue the eyeball into the socket (see Fig. 7). Bore a 7/32"-Dia. hole for the clock shaft in the bridge of the nose. This hole must be clean cut and as vertical as possible. The use of a sharp brad point drill bit and a drill press is recommended.

Final assembly

The entire sun project is edge glued before gluing it to the backing piece. This will allow for insetting the clock movement. Assemble all the pieces on the Pin 'N Press pin-up board protected with wax paper. Edge glue the pieces in place, pin, and allow the face assembly to dry as shown in Fig. 8

Attach the backing and inset the clock movement

Place the face assembly on the 1/2" backing material and trace around it to mark the outline. Note: be sure to mark the center of the hole for the clock shaft.

Set the face assembly aside and drill the clock shaft hole through the backing. Place the clock movement inside the hole and align top of clock movement with 12 o'clock of sun. Trace around the movement to mark the cut-out area to allow the clock to pass through as shown in Fig. 9.

Cut around the perimeter, then cut out the hole marked for the clock about 1/16" larger to give space for the clock movement. Save the scrap cutout to use as a template for cutting an 1/8" piece of plywood for a clock support. Bore the shaft hole in the 1/8" support as shown in Fig. 10.

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