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

Heads up. License Plate Surround Pattern.

It has come to my attention that some states have a law banning license plate frames. Make sure you know your local and state laws before you cut the pattern I posted this morning. Apparently even when the dealer installs the frame with their dealer name those are often not legal. I can't tell from my readeing if the law just requires that the frame not block any part of the plate lettering or if they are just forbidden completely.

Wooden License Plate Surround Pattern.

Want to add a touch of class to your car. Add this wooden license plate surround to your ride and it will stand out. 
The surround will need some protection from the weather. I almost never stain a scroll saw project but in this case it was necessary. I cut the surround from 1/4" red oak. The natural wood did not stand out enough so I stained it with a red oak stain. After the stain dried I finished it with several coats of gloss Spar Urethane spray. The Spar Urethane has a UV protection to help prevent the sun from fading the wood. It also provides a water barrier. Make sure you stain and finish both sides of the project.
The surround looks nice on my Ford Supercrew truck but imagine how nice it will look on your 2014 Corvette.
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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.

Seyco began business in 1986 with the goal to supply the best customer support and quality products in the scroll saw industry. I have worked with Seyco on many occasions and I can tell you they are simply the best. Please do yourself a favor and click the image above. Steve Good

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 here 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. 

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.