Creative Woodworks & crafts 2000-10, страница 26

CORIAN DOLPHIN ON DRIFTWOOD

by Barry Gross "Mr. Corian" of BG Artforms

Patterns Located in Full Size Pattern Section No. 2!

"Mr. Corian"

INSTRUCTIONS

Place the Corian with the smooth side facing toward you. Cover the surface with masking tape. This will help to protect the blade from overheating during the cutting process. Use spray adhesive to attach the pattern to the taped surface (see Fig. 1), then drill the 1/4"-Dia. hole for the eye as indicated. Make all cuts (see Fig. 2), then remove the pattern and the masking tape. Glue the 1/2" long brass pin into the eye opening using CA glue and allow to dry thoroughly (see Fig. 3). Note: this type of adhesive dries in approximately 30 seconds. Once the glue has dried completely, sand the top of the brass pin flush with the Corian surface.

Use the pneumatic sanding drum to shape the edges of the dolphin (see Fig. 4). Note: these edges could also be routed. Once all edges have been rounded over, dry sand using 220, 320, 400, and then 600 grit sandpaper, followed by wet sanding with the same grits. If you have access to a polishing wheel, polish using a muslin wheel and a good polishing compound to buff the surface out nicely.

Make the base

Cut the base piece in the same manner as the dolphin, then remove the pattern and masking tape. The base can be finished in any way you like. Some choose to

SUPPLIES

Wood: driftwood or old weathered tree branch—one

piece in size of choice Corian: blue or green—one piece 1/2" x 5-3/4" x 6" (for the dolphin), one piece 1/2" x 3-3/4" x 8" (for the base)

Tools: scroll saw with No. 7 PCBGB blades*; drill with 1/4"-Dia. bit; pneumatic drum sander*** or router with 1/2"-Dia. roundover bit; belt/disc sander with 5" aluminum oxide sanding discs** (optional); polishing wheel with muslin wheel and a good polishing compound (optional) Temporary-bond spray adhesive Masking tape

Medium grade cyanoacrylate (CA) glue**

Sandpaper, assorted grits

5 minute epoxy

One wood screw

1/4"-Dia. x 1/2" brass pin for eye*

1/4"-Dia. x 1" brass pin to attach dolphin to driftwood*

*AII materials noted are available from BG Artforms in

the Corian Dolphin on Driftwood Kit (No. SLPK1CDD)

for $24.95 (plus $8.75 S&H). Contact BG Artforms at

2189 Philip Drive, Bensalem, PA 19020, (888) 717-

4202; or visit their website at www.bgartforms.com.

**Aluminum oxide sanding discs are also available

from the BG Artforms website in the Solid Surface

Sanding Kit. Cyanoacrylate (CA) glue is available as

well. See address above.

***Available in Drum Sanding Kit Model No. 130, which includes the pneumatic drum sander, four sanding sleeves and one hand pump. The kit sells for $46.95 (plus $9.75 S&H). See ordering information above.

simply round over the edges and sand, leaving the shape simple. The choice is yours.

Optional finishing technique: to give the dolphin and the base a lasting shine with virtually no scratches, use a disc sander with 5" aluminum oxide sanding discs to give your project a professional finish.

Shape the dolphin

Once the sanding is complete, preheat your oven to 340 degrees. Place the dolphin on a cookie sheet and bake for approximately 10 to 15 minutes. Use oven mitts to gradually and very carefully twist the body of the dolphin to the desired shape and depth (Fig. 5).

Assemble

Choose a piece of driftwood or an old weathered tree branch small enough to highlight your dolphin (see Fig. 6). Sand or cut the wood until it is flat on the bottom. If

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Creative Woodworks & Crafts