Mon Jan 12th 2009

Step 1: Brief

Problem: I need to design a Canadian souvenir.

Brief: I decided to design and construct an original piece of Canadian culture; an Inishchock. Although typically they are made of stones stacked on top of one another, I am going to make mine out of wood.

Step 2: Investigation:

How many parts? 9

How would I attach the parts? Glue and Screws

What are the dimensions of the sculpture? 8 x7 x 5.5 (h x l x w)

What size screws should I use? 1 ×8 F.H.

What kind of finish should I use? Varnish

Step 3: Material List

- 1 Wood Plank

- 4 1 ×8 F.H. screws

- Varnish

- Wood Glue Fittings

- 1 ×8 F.H. Screws

- Wood Glue Finnish

-Varnish

Step 4: Tool List

-Hand sander

-Clamp

-Pencil

-Eraser

–Brush

-Scrapper

-Tape measure

-Meter stick

-Water level

-Square

-Portable drill

-Screwdriver

Wood burner

-Band Saw

–Sandpaper

-File

-Edge Sander

-Belt sander

-Router

Step 5: Cutting List

Step 6: Fabrication:

1. Sketch out your 9 parts on the piece of wood using your pencil and measuring tools.

2. Use the band saw to cut out your pieces.

3. Use your water level to check that your sculpture is level. If not, run your incorrect piece(s) through band saw if large enough. If they are small, use the belt sander, file or sandpaper.

6. Sand all the corners and edges of your head piece until roundish on the belt sander

7. Mark the center of the ends of your arm piece and then sand accordingly.

8. Using your protractor, pencil and belt sander, mark and sand very small quarter circle the right angles of your triangular upper abdominal pieces until rounded.

9. Round and sand all the corners and edges on your rectangular hip piece.

10. Round the top edges your top base using the belt sander

11. Run the second bottom pieces top edges through the Router.

12. Use the portable drill to drill your holes in the 4 placements as dictated in the sketches.

13. Glue the head piece to the top center of your arm piece.

14. Apply pressure on the two pieces by clamping them together for about 5 min.

15. Glue the two triangular pieces together to form a rectangle.

16. Apply pressure on the two pieces by clamping them together for about 5 min.

17. Glue the now rectangular upper abdominal piece to the head and arm piece.

18. Apply pressure on the pieces by clamping them together for about 5 min.

19. Glue both leg pieces onto the hip piece with 0.5” between them.

20. Apply pressure on the pieces by clamping them together for about 5 min.

21. Glue the lower body and the upper body together.

22. Apply pressure on the three pieces by clamping them together for about 5 min.

25. Screw the screws up in through the upper base piece holes into the legs.

26. Screw the screws up in through the lower base piece holes into upper base.

27. Using a wood burner, burn the letters you just wrote in order to emphasize the letters.

28. Apply wood filler into the two bottom screw holes using the scraper and your finger.

29. Sand entire project down until it is as smooth as a baby’s bottom.

30. Apply first coat of varnish onto your project using the brush and wait for it to dry.

31. Lightly sand out the imperfections in the first coat and then apply a second coat of varnish.

32. Wait for the second coat of varnish to dry.

Step 7: Evaluation

1. The first flaw in my design is that I did not take the time to dry my brush off, thus mixing the water with the varnish. 2. The second flaw in my design is that I did not burn the wood deep enough.