Intro: Football No Lathe Required!
My decision to make this was that it has not been done on here. I decided to give it to a friend's husband who likes football.
Step 1: Materials
Begin by gathering 3/4" black walnut pieces that are roughly the same size.
Step 2: Gluing
Prepare the clamps for gluing, then start gluing each piece together. Let dry.
Step 3: Cut of Excess
Once the glue has dried, cut or sand off the excess material to smooth up the block for drawing.
Step 4: Drawing and Cutting
Draw your design and cut it out with the bandsaw. Then repeat the process on the other side. The end result should look like the last 2 pictures.
Step 5: Sanding
Once you have roughly cut out the shape of the football you can begin to sand it down with the sander. Make sure you check it every now and then to ensure you get the desired shape.
Step 6: Making the Lines
After getting the piece to the desired shape, mark the middle of one side then the center of the other till you have 4 lines. Once completed cut them only enough to make a noticeable line.
Step 7: Marking the Band's at the Ends of the Football
I free these lines by jand, but you can use a compass. After drawing them out take the rotary tool and cut out them out.
Step 8: Strip for Band
Next you need to cut a strip out of pine (or wood of your chose) to fit. Glue it in place on both ends. Let dry.
Step 9: Middle Strip and Laces
Use the same method as before however, cut 8 small pieces for the laces. Glue them in/on.
Step 10: Clamping Issue/Fix
A issue arises when trying to glue the laces and strip on the football, based on the roundness of the football. To solve this problem I cut a piece of 2x4 to fit the shape of the football. Once cut I covered the area the football was going to be with tape, this was so the 2x4 would not adhere when clamped. Clamp down and let dry.
Step 11: Examination
Upon examination of the football after drying, I found that the laces move during the clamping. :(
Step 12: Fixing and Sanding
I fixed the laces the best I could, and I started hand sanding the football down. I used 100 grit sandpaper and then used 150 grit sandpaper and sanded the entire football down. Make sure you get in between the laces.
Step 13: Coating
After sanding to the desired smoothness, I out on a coat of linseed oil to protect the football. This brings out the darkness of the black walnut and the light color of the pine.
Step 14: Finished
That's it, all done nothing to do but admire your hard work.