Latest woodworking project

Just before Christmas, Kerry got a very nice clock based on a Frank Lloyd Wright ‘Exhibition’ design.  We liked the looks of the clock, but for the space it was in, we wished it was slightly larger diameter.  Also the face was about 3/8″ thick, but, due to the mechanism, protruded from the wall about 1 1/8″.

I decided to frame the clock and wanted to use a ‘shadow’ frame that was round like the clock.  After considering various ways of making a round frame (that was perfectly round since it had to match the clock), I decided to mill a frame from a single segmented piece.

Here is the ‘almost’ finished frame:

Frank Lloyd Wright Clock Frame

Here’s how it was done…

ClockFrame

[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_5008.jpg]3960Clock with frame, waiting to be finished.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4949.jpg]3680It all started from a hunk of Red Oak from some slabs of a tree I had to cut down to build the workshop.
The wood has been seasoning for a little over a year and is 14 feet long, 10-12 wide, and 2 inches thick.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4947.jpg]3500Here's a closeup of the chunk I cut out.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4951.jpg]3460Here's the chunk on my jointer, ready to be flattened.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4952.jpg]3400After flattening and letting it 'relax' for a few days, I marked the specific sections that will be used for the clock frame.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4958.jpg]3370Since this chunk ended up quarter sawn, I decided to slice it so the exposed face would be quarter-sawn.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4963.jpg]3350Close up of each section.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4964.jpg]3330
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4965.jpg]3290
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4966.jpg]3290Close up of each section after ripping.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4967.jpg]3290
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4968.jpg]3270
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4973.jpg]3260Then rejoined after putting the quartersawn face outward.
These give me 3 inch deep boards that can be cut into 30 degree wedges.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4992.jpg]3280Here's the jig to precisely cut the 12 wedges.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4994.jpg]3270All the wedges are glued into two halves.
Doing it in two halves allows any error (which is multiplied by 24 cuts) to be easily sanded out with a belt sander...
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4997.jpg]3250Finished glue up.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_4999.jpg]3270Disk has been flattened and planed down to the final thickness.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_5001.jpg]3320Then the piece is put on the CNC Router to precisely cut the pockets and outside cylinder.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_5002.jpg]3290The backing plate was also cut on the CNC router. The cutout in the middle exactly matches the back opening of the clock.
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_5007.jpg]3270A couple more views...
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_5009.jpg]3230
[img src=https://tomstudwell.com/wordpress/wp-content/flagallery/clockframe/thumbs/thumbs_img_5012.jpg]3170

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