This is my first Instructable. Hope you will follow clearly. It will show you a step by step how to make a spiral out of a solid round piece of wood. Tools needed: Drill press, Table Saw, 10mm wood/steal drill bit,elbow grease, small round file, more elbow grease, sand paper, more elbow grease. Enjoy! by.....AntonD
Step 1: Make a V-Block
To make a spiral, you need to work very precise. Start off by making a V-Block big enough for a 40mm diameter round piece to fit comfortably. See pic. This is where the table saw came in handy. The shape does not have to look like mine. As long as theres a big V-groove in it as to hold the round piece tight.
Step 2: Solid 40mm Piece
Get a piece solid, perfectly round wood (or turn one on a lathe), of 40mm diameter and about 350mm long. My picture shows the ends already shaped. It's better not to, as this makes the next step difficult.
Step 3: Mark With Pencil
Now you need to mark your solid piece of round wood. On both ends, find the center and divide in into quarters (Pic1). Draw lines between the four quarters (Pic2). Now, on the first line, make a mark 25mm from the edge, second line, 50mm from edge, third line 75mm from edge, fourth line 100mm from edge. Now you are back at first line, mark it 125mm from edge. Next 125mm etc. etc. Continue to the next edge.
Step 4: Cellotape
Now, take sellotape, or any other sticky tape of about 12mm width, and stick it all around the round wood only touching the markings you made in step3. This form a spiral. Next, stick another piece of tape all around, exactly in the centre between the spirals of the first tape. Notice the tape in the picture.
Step 5: Drilling
Putt the solid round in the V-Block and position it in a drill press. You should drill from exactly on top. Use a 10mm bit and drill all along the tape (both sides of the tape). You do not need to drill right through the solid. The holes will overlap. My picture only shows the holes on one side of tape. I did not take a pic when all holes where drilled.
Do not rush this drilling part. Be very very carefull, the drill bit must not cut sideways. (Although it tends to). GO SLOW.. I can't remember exactly, but it's about 300 holes with these measurements.
The pieces where the tape is, will form the spirals. The rest will fall out.
Oh, and do not drill all the way to the ends. (Logic)
Step 6: Sanding
Next is where the elbow grease comes in. Unfortunately, again I got carried away and forgot about the camera. I should have taken more pics, but its all straight forward. All I can say: "Be extremely carefull". If you rush, it WILL brake. I used a grinding stone, grinder, file, sandpaper, etc. This is the part where you tend to give up, but it gets easier as you progress. (Wheres my pics). Again, carefull, my first one broke.
Step 7: Fin
And thats about it. Try it and let me know. Cheers. Anton