Tips for turning acrylic

Dear Friends of Xylem Rotating in Circles:

When I presented my acrylic bottle stoppers at Wednesday’s meeting, someone asked how I sanded them.  I sated that I started sanding with Abranet mesh.  One of you said that you had never heard of Abranet, so I thought I’d point you to a source here:  https://www.pennstateind.com/store/PKMESHKIT.html.  This isn’t the only place to buy Abranet, but I have found PSI’s prices to be fairly reasonable.

I also mentioned that after dry sanding to 600 grit with Abranet, I moved on to wet sanding with abrasive pads.  Coincidentally, I received an order of these just a couple of days ago:  https://www.pennstateind.com/store/MMESHPADS9.html.  That price may seem high, but notice that these pads are 3×4 inches.  The ones I currently own are 2×2 inches.  When I went to Penn State, 3×4 offered three times more surface area than 2×2.  So pay close attention to sizes as well as prices if you should order these.  I think they work best wet as a sanding slurry is created when wet that I think helps with sanding and extending the life of the pads.  You can also choose to use a polish on the acrylic after sanding to 12,000 grit.  It’s hard to get much smoother than that.

If you should decide to move into turning bottle stoppers regardless of material, this chuck is essential:  https://www.pennstateind.com/store/PK-BS1-MJ.html.

If you wish to use acrylic, it’s cheaper to buy this size (https://www.pennstateind.com/store/WXACL03L.html) and cut it into thirds, than to buy this size (https://www.pennstateind.com/store/WXABS04.html).  I cut my blanks into three sections with a hacksaw to minimize wear on my bandsaw blades and waste as little acrylic as possible to kerf.  As I stated on Wednesday, this stuff is harder than woodpecker lips, so somewhat different technique is needed than for wood.  But as with other hard materials, it can be fra-gee-lee, like Ralphie’s old man’s leg lamp, so handle accordingly.  Those at the meeting saw what happened when I tried to tap a small hole in my blank to minimize drill bit skating.

Someone Wednesday asked if you can use any lathe chisels to turn acrylic.  My answer is yes, but you have to have a gentle hand and a degree of patience.  If you get too aggressive, you will likely get catches, chipping, etc. that will diminish your fun.  If you use carbide-tipped tools, I recommend negative rake cutters as they are less aggressive than the standard cutters.  I bought this set some years back from Rockler (https://www.rockler.com/carbide-mini-turning-tool-3-piece-set).  As you can see from the price, manufacturers are VERY proud of their carbide tools.  For some time, Rockler stated that they did NOT supply negative rake cutters for these tools, but while visiting a Rockler store in Houston, I complained about that to a store employee who found a negative rake cutter from another manufacturer (I think Easy Wood) and said it would work on my tool.  He was right, and I have been pleased with the result.  I strongly recommend the negative rake cutters.

Mike Messina

February 2023 Meeting

We had officer elections, showed off spheres we learned how to make last month, collected wands for Camp Korey, and watched Tony Omeis walk through all the steps needed to design, construct and turn a segmented vessels.

Spheres and wands were everywhere
Ken brought in a sampling of items from the new club store
Don’s presentation last month inspired many to try their hand at making a sphere
The full selection of wands collected for Camp Korey – Nice work, the kids will love these!
The vessels we learned how to make
The recorded meeting including Tony’s presentation

January 2023 Meeting

This month’s meeting featured an interactive remote demonstration (IRD) by Don Wilson showing us how to turn a sphere, with the tricks he’s learned from making hundreds over his many years turning.

Our show and tell table
Our IRD setup

December 2022 Meeting

We enjoyed some holiday treats prior to our show and tell where we shared the first thing we turned. Some of us started turning months ago, others brought decades old pieces. It was fun to hear how we all started out. Ken Vasko also demonstrated how he makes several different Christmas ornaments and decorations.

Our first projects
Ken’s handiwork

October 2022 Meeting

Paul Demmert showed how 8 different finishes look on bowls made from the same wood and ranked and rated them on various attributes. His notes are below the meeting video.

The genesis of this presentation was a presentation the club had several years ago with Jim Finley talking about finishes.  The idea that took root in my mind was to show a variety of finishes on bowls that were all the same kind of wood.  This would allow a comparison among the different finishes.

About 1 year ago I got access to a large log of American Holly and that was an opportunity to build this presentation on the different finishes.  American Holly, Ilex opaca, is a species of holly, native to the eastern and south-central United States, from coastal Massachusetts south to central Florida, and west to southeastern Missouri and eastern Texas.  It is the state tree of Delaware.  Ilex opaca is a medium-sized broadleaved evergreen tree growing on average to 10–20 m (33–66 ft) wide canopy, and up to 30 m (98 ft) tall. Typically, its trunk diameter reaches 50 cm (20 in), sometimes up to 120 cm (47 in). The bark is light gray, roughened by small warty lumps.  The wood is very pale, tough, close-grained, takes a good polish, and is used for whip-handles, engraving blocks and also cabinet work.  (specialty items such as fancy cabinet inlays, small pieces of furniture, brush backs, handles, novelties, wood engravings, scroll work, woodcuts and carvings, and measuring scales and rules for scientific instruments).  Ideal lumber has a very uniform, pale white color with virtually no visible grain pattern. Janka Hardness: 1,020 lb (red oak 1290, black walnut 1010, cherry 950)  

Because Holly has such a subdued grain pattern, it takes coloring dyes very well.  Because of this, Holly can be dyed black and used as a substitute for ebony–for piano keys, violin pegs, and fingerboards.  Knots are common, which can reduce the usable area of the wood.

Holly is usually cut during the winter and kiln dried shortly thereafter to preserve the white color of the wood.  Holly can develop a bluish/gray fungal stain if not dried rapidly after cutting and this will be evident on the bowls I have for this presentation, because I didn’t get the bowls turned until over 6 months after it had been cut down in the late summer to early fall.

I have turned holly once before and that was a tree that had been cut down at my Father-in-Laws house and my wife grabbed a couple of sections of that tree after it had been hauled off to the dump.  I turned that holly green, right after Leslie got it home so the resultant bowls were pure white, with no visible grain, almost like porcelain.  Again this holly was turned within a month of being cut down.

This wood came from a landscape company in Altoona.  In the fall of 2021 I went to pick up the wood.  It was a single log, 8 ft long, 12-14 in diameter.  The worker helped me by cutting the log into sections that were 16-18 in long, weighing about as much as a single person could carry.   I stored the sections in my basement and painted Anchor Seal on the ends of the sections to seal the end grain.

Later I cut the sections in half with my chainsaw, right down the pith, giving me 2 bowl blanks per section.  

I turned all of the bowls from March 6 to April 9 2022.  All of the bowls were turned green, with the foot of the bowls pointing to the bark part of the blank, the inside of the bowls oriented towards the pith or the center of the tree.  These bowls were only turned once, air dried for about 5 months (from April to August), and hand-sanded.  Note that my bowls are functional, rather than artistic—wall thickness is between 3/16 to 3/8 inch.  There was some movement in the bowls during drying, but some bowls help their shape pretty well.  None of the bowls were remounted for a second turning.  I started finishing the bowls in late August and applied last coat in early October.

Finishes Used

#1  Shellac (1# cut) dewaxed super blonde flakes dissolved in denatured alcohol

#2  Total Boat Varnish Clear Gloss

#3  Minwax Polycrylic Clear Satin

#4  Minwax Spar Urethane Clear Gloss

#5  Behlen Mohawk Salad Bowl Finish Clear

#6  Watco Danish Oil

#7  Deft Brushing Lacquer

#8  Waterlox Original Tung Oil

Procedure

220 grit First coat 

320 grit Second coat 

400 grit Third coat

600 grit Fourth coat 

Total coats of finish:  6 or more

Buffed with white pad = 0000 steel wool to knock off dust nibs

Results

Various differences between the finishes include how does it flow (drips, brush marks, drying time), the general appearance of the finish, the cost, and cleanup.

Flow

Finishes that flow nicely:  shellac, Minwax Spar Urethane, Behlen Mohawk Salad Bowl, Watco Danish Oil, Deft Brushing Lacquer, Waterlox

Others:  Total Boat Varnish and Minwax Polycrylic tended to be thick and left drips (better when thinned with water)

Deft Brushing Lacquer has levelling agents that almost eliminate brush marks.  

Shellac, Total Boat Varnish, and Deft Lacquer dry very fast.

Watco Danish Oil very slow drying and stays tacky 

General Appearance of the Finish

In this demonstration, I did not try to sand and buff out the bowls to make them perfect.  Some of them still have brush marks and other defects in the finish that I need to address.  I wanted to concentrate on the impression the finish makes on the viewer.  This is very subjective.  Also remember that results are dependent on the wood species—particularly if you are looking to see how much the tone of the wood has darkened after finish has been applied.  This would not be a consideration if the bowls were turned from walnut, cherry, hickory, or other darker woods.

From my perspective #4, #3, #7 and #2 take on the “best” appearance, because these bowls still retain a lighter tone that is more consistent with the lighter color of Holly.

Bowls #6 and #8 come in at the end of the pack for the same reason—they darken the tone of the wood too much.  Even though, #8 has a nice looking finish overall.

Cost

Most of the cost figures used in my analysis come from the prices I paid, either through Amazon or at local stores like Ace Hardware, Lowes, and Home Depot.  If you took the time to shop around, you probably could beat the prices I paid.  

#1 Minwax Spar Urethane Clear Gloss ($18.86/qt)  

#2 Shellac (1# cut) dewaxed super blonde flakes dissolved in denatured alcohol (Flakes $2.20/oz, DNA $4.00/8 oz,= $24.80/qt         Zinsser $26.53/qt)     

#3 Watco Danish Oil ($24.99/qt)    

#4 Deft Brushing Lacquer ($26.13/qt)     

#5 Waterlox Original Tung Oil ($32.83/qt) 

#6 Behlen Mohawk Salad Bowl Finish Clear ($40.45/qt)     

#7 Total Boat Varnish Clear Gloss ($44.00/qt)    

 

8 Minwax Polycrylic Clear Satin ($55.60/qt)        

Cleanup

Water soluble:  Total Boat Varnish, Minwax Polycrylic

Mineral Spirits:  Behlen Mohawk Salad Bowl, Minwax Spar Urethane, Waterlox, Watco

Lacquer Thinner:  Deft

Denatured Alcohol:  Shellac

Reeds Gap Fall Festival

The Reeds Gap Fall Festival, Saturday Oct 8th, was a great success. We had a lot of interest in woodturning and our club. There was about 1200 people at the event. It was a lot of fun and we met a lot of good people.

Special thanks to Travis Gross, Brian Hummel and S. Bear for helping setup, turn, schmooze the crowd, tear down and clean up!

New club member is a great demonstrator. He drew a crowd for sure.

September 2022 Meeting

Our first meeting after the summer break was a nice relaxed time to catch up on what everyone had been doing and making over the summer with a big show and tell and Q&A time. Held at the normal place, at the normal time – The RIvet at 7pm on the first Wednesday of the month.

June 2022 Meeting

This meeting was a Saturday Shop Tour, June 4th, where we went to five member shops to see how each were set up and what goodies they used to make their creations. It was a great time to hang out and learn from each other.

May 2022 Meeting

Our hybrid meeting held at the Rivet included a demonstration titled “From Log To Bowl’ by Stephen Tuttle. We learned how Stephen makes decisions on everything from chainsaw safety to mounting the lumber, to rounding a bowl blank, to basic sharpening. Great tips, reminders and examples for everyone.