Bonsai from Big Sagebrush




The following photos show the steps for constructing a whirligig hub with wood blades attached directly to the wood hub.

For this whirligig two hubs are needed. First cut square shapes from 3/4" (1.9cm) stock. I'm using African mahogany here, because it's ideal for exterior use and works easily. The dimension of the square is the same as the diameter the finished hub, in this case 2 7/8" (7.3cm.) I mark the center of the hub.

I have drilled a pilot hole and marked the location of the 1/2" (1.3cm) deep by 1/4" (.64cm.) wide groove to receive the blade. I only need to mark up one side of the square, because I'll use this for setting up my jig to cut all the sides the same. If the direction of the blade pitch is important, do it here. This set of blades will rotate in a clockwise direction.

The jig is a simple L-shaped assembly, which I clamp to the table crosscut slide at 45 degrees. I clamp the hub block into the corner of the jig and cut the groove with a dado blade.

The hubs with their grooves are ready to be cut into circles.

With the hub firmly clamped in place on an auxillary drill press table, I cut the hub into a disk using a General Tool circle cutter.

This is the hub from the circle cutter. The circle cutter has a 1/4" (.64cm) drill bit, so the center hole is ready to receive the 1/4" brass shaft. The triangular cross sectioned shape at the edge is from the shape of the circle cutter blade.

I cut most of the waste from edge of the hub on a band saw. With a simple jig clamped to the drill press auxillary table and a 2" (5.1cm) diameter sanding drum, I sand off the remaining waste.

Here is the hub with the blades ready to be assembled.

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