Creative Woodworks & crafts 2002-04, страница 26

by Robert J. Hlavacek Sr. of Wildlife Intarsia Designs

SUPPLIES

Material: alternative ivory*—one piece 5/16" x 3"-Dia. (for the bolo), one piece 5/16" x 1-1/2"-Dia. (for the necklace)

Tools: scroll saw with No. 2/0 crown tooth blades; drill | press with No. 60 bit and assorted sanding drums with i 120 grit sleeves; finish sander; hot melt glue gun and | glue sticks; buffing wheel with white rouge compound; f flutter wheel (optional); pliers •

Sandpaper, assorted grits (up to 600 grit) ■

Temporary-bond spray adhesive {

3/8"-Dia. and 1/2"-Dia. dowel rods approximately 4" long i Cyanoacrylate (CA) glue, thick and thin Quick set epoxy

Bolo clip, cord, and tips* (colors of choice) «

18" chain, screw eye, and jump ring** (gold color)

Jim Dandy Super Sander*** \

*Alternative ivory and bolo tie hardware available from

Treeline, call 1-800-598-2743 for a catalog.

"'18" necklace chain, screw eye, and jump ring available )

from Wildlife Intarsia Designs, Item No. ST-18. Complete [

hardware set for one necklace $2.98 postpaid.

Call 1-708-788-6455 for a catalog.

***Super Sander is available from Wildwood Designs.

Call 1-800-470-9090 for a catalog.

IB • Creative Woodworks S. Crafts April S002

INSTRUCTIONS

The shark teeth in these projects were made from a polyester resin material formulated to resemble ivory or bone. It cuts, shapes and polishes easily, resulting in a realistic looking shark tooth.

The bolo tie

To get a grip on the material for sanding, attach a block of wood to the back of the disc with a dab of hot melt glue. Don't use too much glue or you may have a hard time removing the block later. Sand both sides smooth with a finish sander and 120 grit abrasive (see Fig. 1).

Attach the pattern with spray adhesive. Cut out the shark tooth with a No. 2/0 crown tooth blade (see Fig. 2). Saw speed wasn't a factor when cutting this material as it did not melt back together like acrylic plastic has a tendency to do. When you need to clean the dust out of the cut edge, use an old toothbrush.

Hold the pieces together and trace the outline of the bolo clip on the back side of the cut-out tooth with a pencil (see Fig. 3). Bevel the back edges of the tooth to slightly less than half the thickness, taking care not to sand the area behind the bolo clip tracing. Also bevel the back edge of the top section (see Fig. 4).

Apply a dab of hot melt glue to short lengths of dowel rods and attach them to the backs of both sections of the tooth. I used a 1/2"-Dia. dowel on the lower piece and a 3/8"-Dia. dowel on the upper piece. Using the dowel for a handle, contour the front of the tooth (see Fig. 5). Use the finish sander with 400 and 600 grit paper to smooth out the front of the tooth. After sanding the lower portion of the tooth, hold it in place against the upper piece and trace its contour on the edge. Now contour the upper piece using the pencil line as a guide (see Fig. 6).

A 180 grit flutter wheel, run at about 1500 r.p.m., can be used to smooth the pieces. Take care so as not to sand away the serrated edge of the tooth. Use a Jim Dandy Super Sander to further shape the edges of the tooth. You'll find that it does a great job here (see Fig. 7).

Polish the tooth with a cloth buffing wheel and white rouge at about 2300 r.p.m. (see Fig. 8). Note that the pieces of the large tooth for the bolo were buffed before gluing them together, while the small tooth for the necklace was buffed after it was glued. After polishing, remove the dowel rods by gently twisting to break the hot melt glue joint. If the glue sticks to the tooth, it can be easily rolled off with your thumb. Place a sheet of wax paper on a flat surface. Put a few drops of thin CA glue on one edge of the tooth and hold the pieces together until set (see Fig. 9).

Use a hard flat sanding block with 100 grit paper to roughen and remove any wax paper residue from the back of the tooth. Also roughen the back of the bolo clip. Attach the bolo clip with quick set epoxy. Use enough epoxy so it comes up through the holes in the clip. To finish your tie, press down the center of the bolo clip and feed the cord through the clip from the top (see Fig. 10). Put a little thick CA glue or quick set epoxy in the bolo tips and insert the ends of the cord.

The necklace

Sand the material and cut out the tooth following the same steps as for the bolo tie. Bore a hole with the No. 60 bit through the top section of the tooth for the screw eye. The hole can be more easily bored from the bottom and should be centered on the thickness of the material (see Fig. 11).

Once again use a 3/8"-Dia. dowel rod and a dab of hot melt glue to get a handle on the tooth for contouring. After contouring, remove the dowel rod and glue the pieces together with thin CA glue. When the glue has set, reattach the dowel with hot melt glue and buff (see Fig. 12).

Open the jump ring from front to back. This will help retain its shape compared to opening it to one side, which may make it out of round. Slide the ring through the screw eye and around the chain, then close the ring with pliers.

Present one of your creations to your significant other and then head out to a good fish fry for dinner! jfj

s continued on page 28