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My local hardware store recently offered cheap spruce boards.
Well... most of the stuff was actually unusable but the price was too tempting and one of the boards showed a nice grain pattern. After sifting throug the rest of the pallet I finally found 3 boards I liked and decided to try a Finish "Kuksa"...

Step 1: Modelling...

  • The cup is modeled in Alibre Design. Quite simple and done in just a few minutes...
  • If you like you can download the model and all other files in the "Projects" section at www.estlcam.com.

Step 2: Cutting and Glueing Blanks...

  • To save material and cutting time I've decided to cut slightly oversized blanks rather than machining a rectangular block...
  • The cup is about 85mm high so the best five 18mm blanks are selected and glued together...

Step 3: Alignment Template...

  • To make alignment easy the cups outline is cut into the spoil board...
  • Then the whole block is glued to the spoild board with 5 minute expoxy resin...
    Bad Idea??? Well wait until later ;-)

Step 4: Machining the Upper Side...

  • The tool I've used for roughing is acutally not long enough to cut down to the bottom.
    But it is long enough to clear the inside and reach a level deep enough to pass the largest dimensions in the X/Y plane so it doesn't matter because we can later flip the part and machine the rest from the other side...
  • Finishing is done with a ball nose end mill...

Step 5: Releasing the Cup...

  • So how do we separate the cup from the spoil board?
    Well... many fast curing epoxy resins are heat sensitive and will get soft at temperatures above 100°C. If you put them into the oven and wait a few minutes the cup will just fall off... But check your resin first - I've used "Krick 5 Minuten Epoxy" and "Uhu Sofortfest" will also work but some will not...
  • Another solution is non-waterproof wood glue...

Step 6: Machining the Other Side...

  • This time precise placement is absolutely crucial.
    If you're off by 0.1mm you'll have to sand a lot and if you're off by 1mm you can throw the part into the bin...
    So again I've cut a snugly fitting template to align the cup automatically with perfect precision...
  • My template cut is 5mm deep. To get the correct shape I've just created a temporary cut view where the topmost 5mm are removed...

Step 7: Roughing and Finishing the Other Side...

Step 8: And Finally the Handle...

  • Again a template is cut to align the handle perfectly...
  • For the handle hole I've created a separate STL file showing just the hole and put the origin into its center...

Step 9: Final Steps...

  • After machining the cup is sanded to remove the remaining glue and get a nice surface finish...
  • Finally I've applied walnut oil to highlight the woods grain (use only walnut or linseed oil - most other vegetable oils will spoil)...
I believe this is called a kuksa.
<p>Very good, this I will make.</p><p>Thanks </p><p>Ken</p>
<p>Why not mill each blank individually, and then glue them together? You could take slices of your model set for the thickness of your boards, and go from there.</p><p>This would mean that you could work with a smaller rough cut, and not worry about the ultimate depth of the cup- it could be as deep as you like.</p><p>If you kept the blanks attached to the board with a few tabs, you could even ensure that they were properly registered, so fewer worries about flipping them over.</p><p>The downside would be the more complicated finishing and gluing elements, but it should be at least comparable to what you have to do now.</p>
<p>A great idea, well executed. However I think the wild grain patterns are so chaotic that they detract from the overall picture. Just too much going on. </p>
I understand what you're saying however I think that adds to the charm of it.. different strokes for different folks I guess.
that looks really cool. I'd expect that to be expensive if I saw that in a store. u got skills my friend. well done
<p>that is the most elaborate cup I have ever seen! good ible</p>
<p>Very nice.</p>
<p>Spectacular! The grain patterns really did turn out gorgeous.</p>
<p>cool stuff!</p>
<p>Very impressive work, and the grain patterns are wild!</p>

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