voiceover:the woodwhisperer is sponsored by powermatic, the gold standard since 1921 and by clear vue cyclones, clear the air and breathe easy. marc:have you ever thought about building your own wooden clock? yeah, me neither butapparently people do it. a couple of years agomy buddy rick urschel sent me a whole bunch of footage of him
building a wooden clockwhere he cut all the gears and did everything by hand. absolutely awesome process, very tedious and it took me this long toget around editing the footage but it's finally done and i got a little video here to show you exactly what this process looks like. let's head over to rick'sshop and see how it's done. (lively music)
rick:hi, my name's rickurschel aka patty chuck and welcome to my woodshop. this clock that i'm buildingis a gift for my daughter eli and although she's only eight months old, i hope this is somethingi can pass on to her when she eventually moveson and starts her own life. the clock i'm going to build was designed by a gentlemannamed clayton boyer. the design of this clock is very forgiving
and has a great introduction to the art of building wooden clocks. (mellow music) marc:each wheel begins as a drawing that gets glued to a piece ofplywood using spray adhesive. all critical components should be made from high quality plywood for the sake of stability. rick is using a mahogany ply
from aircraftspruce.com. to cut the gears, thescroll saw is outfitted with a 12 and a halftooth per inch, 5r blade. for the inside cuts, a simple drilled hole provides a starting point. after cutting, the teeth can be cleaned up using a sanding strip in the scroll saw. after the wheel has been cut out, the paper is removed using some naphtha.
the paper usually peelsright off of the wood. this is the escape wheel, the part of the clock thatgives it the ticking sound. it's critical that the tipsare crisp and concentric by mounting the wheel on a shaft, the tips can be sandedto perfect concentricity. the cannon pinion receives a through hole and a countersink. to maintain concentricity,
the blank is taped to the table surface. the larger countersink is drilled first and the smaller throughhole is drilled second. some parts will receivea hole between two teeth that holds then tap to createthreads for a set screw. all the frame pieces are made out of three quarter inch solid maple. the parts are cut outthe same way as the gears using the provided templates.
a chisel is used to make anotch for the drive gear. the one shaft support fits into a dado on the front of the main frame. a dado stack at the table saw removes the material oneither side of the shaft and a dial caliperverifies that the support is only a few thousands widerthan a notch in the frame. a few passes with some sandpaper should produce a nice snug fit.
the drive gear assemblyconsists of the drive gear, the pulley for the weightchord and the click gear. the parts are gluedtogether using a drill bit to hold the parts in positionwhile the glue dries. the intermediate wheel assembly consists of theintermediate wheel, a spacer and the intermediate pinion. the third wheel assemblyconsists of the third wheel, a spacer and a third pinion.
the escape wheel assemblyconsists of the escape wheel, a spacer and the escape pinion. small breast tubes are then inserted into the assemblies using an arbor press. the frame consists of eight parts. everything gets glued and clamped together and screws are added through the back side of the rear frame for extra support. that may seem like a lot of clamps
but you need to do whatever is necessary to get good glue contact. the rear vertical frame is then glued to the main frame. the brush shafts needs to be polished before they're pressed intothe rear vertical frame. using the drill press andsome polishing compound, the shafts take on a nice shine. the shafts are then pressed into the frame
with an arbor press and adead blow hammer where needed. with the gears in place,it's time for fine tuning. by spinning the gears manually, the floss becomes obviousas the gears simply bind up. a rotary tool is used torelieve some of the material from the pinion teeth andthen we can test again. there's only a few teeththat bind up this time so we'll use the rotary tool to relieve the offending material.
when the gears turn freely,the fine tuning is done. you can even blow on the gears and they should turn freely. the pendulum bob is madefrom three pieces of walnut. the inner piece is cut to rough shape and then glued to a backer. this creates two pockets where led shot can be added for extra weight. a precut piece of walnut seals the deal.
once the glue is dry, the bobis cut to its final shape. a two pound cut of shellac is applied to the face of the gears, taking care to get nofinish on the gear teeth. a total of three coats is applied. with the clock dry assembled, a four pound weight is addedto test the clock's movement. the clock will likely stopnow and then as it breaks in but the weight can be adjustedfor optimal performance.
the clock hands are made frompurpleheart and canarywood. after rough cutting, theparts are glued together and then shaped at the disk sander. the center is then cutout of the scroll saw for a decorative effect and a rotary tool is usedto further shape each hand. the clock face is then cut from a sandwich of maple and walnut. the clock weight will bemade from a steel tube
capped off with walnut. the tube will be filled with led shot, bring you this close tofour pounds as possible. the remaining clock parts we finished with general finishes enduro-var, a high quality water based finish. now it's time to hang the clock. rick:the clock's beenrunning pretty steady now for about three weeks.
i had to make just a few minoradjustments to the pendulum but its finally found its home and this is now the secondwind that we've been on that the time has been just perfect. it will ran about 26, 27hours or so on a wind. every morning we get up,we wind the clock, yeah. that's it. thanks a lot for comingon this journey with me and i hope it's inspired youto try and make your own clock.
it is a very easy thing to do. you really don't need a lot of tools. all you need is a lot of patience. best of luck. want to say goodbye? say goodbye.
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