Thursday, June 26, 2014

Meet Dave Kettunen, Master Scroll Saw Artist.

- Here is a treat for you guys. I want to introduce you to Dave Kettunen. Dave is a scroll saw artist who enjoys just a bit of a challenge. In this post Dave gives a run down of what it takes to build the York Minster Clock. The pattern for this clock is available here Wildwood Designs.

Thanks Dave for the wonderful look into your shop.

The images are of the York Minster laid out on the floor of my work shop (minus the floors of the clock) and the syringe with florist's clay for sealing the needle. me at the saw, another of just my saw and red oak cut offs ready for resawing and planning.  I got a hell of a deal on red oak cut offs from a local high school wood shop ($50 for a pickup bed filled).  I use pine runners to eliminate snipe waste from these short pieces.  On most of my clocks, if you don’t make your own boards, you probably won’t be able to afford the wood to make these clocks.  Also resawing allows me to “book” mark boards for gluing to make wider boards.

This clock (York Minster in red oak) is the latest of the larger cathedral style clocks that I’ve cut.  The first being the Dome Clock with Base in red oak; two Orleans Cathedral Clocks, one in cherry and one in black walnut; Roman Cathedral in red oak and lastly The Chimes of Normandy in black walnut.  I have several copies made off all the plans I buy (local copier shop).  The original (marked as such) goes in a file and one of the copies is cut up and scanned into my computer.  I have a light table for taping patterns larger than 8 1/2 x 11”.  Since there are multiple pieces of the same pattern number you don’t want to pay for all those copies.  Also if you make a boo boo on a piece, just bring the file up and print out another.  I know it’s a pain to do all this work, but believe me, it’s worth it in the end.  The second copy is used as a reference for assembly.

I have three plans for intricate scrolling (York Minster, Amiens and the Shopiere) and of the three I decided to to the York Minster first (no special reason).  Here’s the specifics; about 16 hours to make all the boards (I resaw and plane my own lumber), about 5 hours of drilling the holes, 143.2 hours for all the scrolling, 103 Olson #3 Machine Speed Blades, 10 Olson #2 Machine Speed Blades and 3 #1 blades (mfg. unknown).  I don’t have an estimate on gluing the pattern to the wood nor removing the paper afterwards.  Because of the length of time between putting the pattern on the wood, cutting and removing the pattern I would NOT recommend putting the pattern on over painters tape.  The tape may not come off.  Incase anyone wonders about the cutting time, I have a resettable hour meter on my scroll saw (by the way it’s a Hagner V22) so when the saw is powered up, the timer runs.  Threading the blade and blade changing are all part of scrolling and that time counts also.

This plan calls for 450 pieces and 3,743 inside cuts.  About 95% of the clock is cut from 1/4” material with a few pieces 3/16”, 1/8” and - 3/32”.  There’s 16 Pinnacles cut from 1/2” and the cuts are double sided.  There is a lot of repetitious cutting (up to 16 identical pieces) so be prepared to get bored when tackling these.  You will need a router (in a table with a fence) and a 90 degree bit to route the face grooves in a number of pieces (there’s no other way to do this).  I also used this bit to bevel the 90 degree angles where called for.  There is beveling on some of the 1/8” pieces so keep a close eye on your fingers when beveling these small pieces.  I try to precut all the pieces to width and length to save time and fit up later but I still end up doing some trimming during fit up.  I used Elmers Carpenter Wood Glue thru out and found that a 12cc veterinary syringe with a 16ga needle (tip filed flat) to be extremely helpful in applying the glue.  I also use silicone rubber bands to hold the smaller pieces together while gluing.  These bands will not stick to the glue squeeze out.  Finally when the assemble was completed (I don’t have a time for assembly), I took it outside where I sprayed it with numerous coats of lacquer using a detail spray gun.  I still have to install the lighting yet.

On all future work I will be using a product called scrollers tape I get from Scroller LTD.  This is the next best thing since sliced bread.  It goes on easy, the pattern is applied/positioned to the wood and pressed down.  Saw and remove the pattern.  The tape leaves no sticky residue and you can leave the spray glue and mineral spirits in the can.  The tape is somewhat pricy but not breathing fumes is a lot more healthier.  I used this material on the thinner stock and had no problem with removal even on the 3/32” pieces. 

This tape really shines when it comes to cutting puzzles when it’s time to remove the pattern from the pieces.  You don’t need a separate cover sheet.  I use 1/4” 5 ply underlayment, two coats of varnish sanded between coats to seal the surface, apply the puzzle pattern with contact cement, spray the pattern with several coats of clear lacquer and apply the scrollers tape and grid and cut.

Here are a couple more clocks. The first one is The Dome Clock and the second is The Chimes of Normandy Clock. Both are available from Wildwood Designs. 

Dave Kettunen

This is the end of the daily posts. Keep scrolling for lot's more scrolls saw fun!
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Heritage Wood Specialties is a nationally recognized supplier of superior quality hardwoods to fine woodworkers across the US and Canada. Novice hobbyists and experienced enthusiasts alike can enjoy the high quality woodworking materials and kits available from Heritage Wood Specialties. Great source for scroll saw ready boards.

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Free Pattern Catalog. 1000's of free patterns.

Thousands of FREE scroll saw patterns. No registration or signup required.

The projects form these patterns can be sold without restrictions. The patterns cannot be sold.

Click her for the Free Online Catalog.


Wooden Vases on the Scroll Saw Book $12 Each
Each digital book is available for download immediately after payment.
The books are $12 per edition and contains eight unique patterns each.
Watch the following video to see how easy these beautiful scroll saw vases
are to make. 

CATALOG DVD $20+ Shipping

Do you want all the patterns available from the Scrollsaw Workshop? This DVD has every pattern published from 2007 thru 2017. This DVD has 2,300 patterns. The DVD is $20 plus shipping to many countries in the world. Check the order page for details.

No returns are accepted. No refunds. Defective DVDs will be replaced.

Create a Family Heirloom. Download The Jigsaw Puzzle Template Book. Only $7.00

May not print correctly from a mobile device. Use a desktop or laptop computer for printing. Instructions included for printing
Create one of a kind jig saw puzzles. Imagine how thrilled they will be when you create a hand cut wooden jigsaw puzzle of their photograph. Wedding and anniversary photos, birthday or special occasion.
Watch this video demonstration to see of the templates being used to create a wedding puzzle.

You will be directed to the download page after your purchase for instant download.

This pattern book contains the following size patterns

5x5 25 piece

4x6 24 piece

5x7 35 piece

8x10 80 piece

4x6 96 piece

5x7 140 piece

8x10 320 piece

Important: On the successful payment page click the Return to Merchant button to be directed to the download page. This pattern book contains only the puzzle patterns. No pictures are included. The book is in Adobe pdf format and requires Adobe Reader to view. This is a download only. If you wish to pay by check please include an email address and I will send the file to you. I can not mail a disk or print of the book.

Order the $3 pdf Catalog

This is a PDF of all the patterns in my free catalog. It is for Windows only and has a program to automatically download the pattern to your computer. Please watch the video below before you order. Click the picture to order.
You do not need a PayPal account to order. At the bottom of the PayPal page is a button that will allow you to pay with a credit card. After successful payment click the Return to Merchant button for the download.

Stencil Printer 1.7

Stencil Printer Instruction Video.

The Scrollsaw Workshop Stencil Printer 1.7 is my latest software for creating patterns. It will create key chain fobs, desk name plates and more. Click the image above to download the latest version. It is free to use donationware. This software is for Windows PC only.

Scroll Saw Pattern Printer update 1.1

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Download the Free Scroll Saw Pattern Printer Version 1.1. Create name patterns in seconds. Windows PC only.
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Please consider a $5 donation for The Scroll Saw Pattern Printer v1.1.

Scroll Saw Keychain Pattern Maker

Use the Scroll Saw Keychain Maker to start a small keychain business. Build yourself a nice display and make up severl keychains with common names. Sell at craft shows, on Ebay or at work. Everyone needs a keychain. Take custom orders. Heck just make them and give them away as gifts. It's all made easy with the Scroll Saw Keychain Maker. Watch the video demonstration then download the file below and get started with the fun.
The following link will start the download process. After the file download is complete just click the setup file and the program will be installed. Please consider a $5 donation for the program.

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Please consider a $5 donation for The Oval Key Chain Pattern Maker.

T-Shirts and More.

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Charles Dearing Portrait Pattern DVD's

If you want to make your own portrait pattern designs this may be what you are looking for. Charles Dearing has a unique approach to designing portrait style patterns. He does not use complicated computer software. He uses good old pen, paper and tracing. Charles teaches everything you need to know to take your picture and turn it in to a beautiful wooden treasure. Click this link now and see the DVD's he has to offer.

The Lifter

Papa's Custom Patterns.

Sheila Landry Designs

Sue Mey Scroll saw artist

Sue Mey Scroll saw artist
Make sure you visit my good friend Sue. She is one of the finest scroll saw pattern designers in the world today. .

Philip Lowndes Noah's Arc Pattern Available. Watch the video below.

This video is from Philip Lowndes. He is the designer of this beautiful Noah's Arc puzzle pattern. If you would like the pattern follow the link below.
Buy This Wonderful Heirloom Puzzle Pattern

Think Safety

Remember to keep the safety of yourself and others in your work shop in your thoughts at all times. Always wear eye and ear protection. Follow all the manufactures warnings that came with your power tools. If I demonstrate something on this web site that you don't feel is safe, don't do it. Your safety is your responsibility. Fingers are handy things, try to keep all of them.
The Scrollsaw Workshop Blog is in no way affiliated with or sponsored by Scroll Saw Woodworking and Crafts Magazine formerly (Scroll Saw Workshop Magazine) or it's publisher Fox Chapel Publishing.

Scroll Saw Woodworking and Crafts