Research of Components, Processes, Technologies, and Resources

Finishes

Past Clayton BoyerDesigns

SN- 31487307

4

RESEARCH

Timbers

Existing Designs

Technologies

Glues

Processes

Orreries

Crank Mechanism

Carcass

Gears

Planets Pegs

Carcass

Gears

Planets

Scotch-Weld

PVA

Purbond

Routing

Mitre Joints

Biscuit Joints

Turning

Laser Cutter

3D Printer

Dremel

Pedestal Drill

Table Saw

Compound Mitre Saw

Table Router

Wood Lathe

Research of Components, Processes, Technologies, and ResourcesExisting Designs:

Name: Plus: Minus: Interesting:

Copernican Orrery by Dan Durdle (from Clayton Boyer’s plans)(Image Source-https://www.flickr.com/photos/lisaboyer/4107585978/in/album-72157625772416530/)

o Gears are clearly visibleo Simple design

o Unappealing materials and colours

o Just the base design from the plans

o Small size of planets makes top very uncluttered

Name: Plus: Minus: Interesting:

Copernican Orrery by Greg St. George (adapted from Clayton Boyer’s plans)(Image Source-https://www.flickr.com/photos/lisaboyer/44533866891/in/album-72157625772416530/)

o Appealing materialso Dodecagonal shapeo Zodiac sign designs on

the side panels

o Plywood gears don’t fit more premium carcass

o Interior is very dark

o Use of gold accentso Railing around the top side

Name: Plus: Minus: Interesting:

Copernican Orrery by Bob Tiews (adapted from Clayton Boyer’s plans)(Image Source-https://www.flickr.com/photos/lisaboyer/5172744601/in/album-72157625772416530/)

o Appealing materialso Dodecagonal shapeo Side panels are clear

but still have zodiac designs

o Starfish design for top instead

o Plywood gears don’t fit more premium carcass

o Gold posts take away from general appeal of the gold accents

o Crank handle is tiny

o Etching the clear panels with a design

o Zodiac symbols on top plate as well

o Gold planetso Routed top and bottom plates

SN- 31487307

5

Existing Designs:

Name: Plus: Minus: Interesting:

Copernican Orrery by John Rowley(Image Source-http://www.liming.org/orrery/pics/rowley.jpg)

o Detailed, 12-sided design

o Carved elements

o Very ornate, looks oldo No open topo Too much going on

o Dome shape at the top

SN- 31487307

Research of Components, Processes, Technologies, and Resources

Based on the orreries that people have constructed from Clayton Boyer’s plans, I want to change the external carcass to a hexagonal or dodecagonal shape. In order to show off the mechanism I will use a combination of clear and solid panels as well a filigree top plate to allow for good visibility and light. I will also involve the zodiac signs/symbols as carvings or engravings on the side or top of the orrery. Although the gold accented orreries look good, I will stick to using timber and just use different colours in order to get a similar effect. I will also turn my planets out of wood instead of using plastic or metal ones.

Although the ornate design of the older orrery is impressive, it is too complicated and busy. In my own design I would like to include some more ornate details such as a fancy mouldings, but in general keep a simpler and cleaner design in order to modernise it.

Existing Designs Evaluation:

Timbers- Carcass:

Common Name:Jarrah

Growth Areas:South-West Australia

Properties:o Interlocked graino Average to worko Turns wello Glues wello Finishes well

Uses:o Cabinetryo Flooringo Furnitureo Constructiono Turning

Potential Health Risks:o Sensitisero Irritant to nose, eyes

and throat Botanical Name:Eucalyptus marginata

Availability:Widely

Image Source- https://brittontimbers.com.au/timbers/jarrah/

Common Name:Tasmanian Blackwood

Growth Areas:Tasmania

Properties:o Usually straight graino Easy to worko Turns wello Glues wello Finishes well

Uses:o Veneero Furnitureo Cabinetryo Turning

Potential Health Risks:o Sensitisero Contact dermatitiso Bronchial asthmao Irritant to eyes, skin,

nose and throat

Botanical Name:Acacia melanoxylon

Availability:Widely

Image Source- https://gfethers.com.au/wp-content/uploads/2015/11/GF_TASMANIAN-BLACKWOOD-67423-727x1024.jpg 6

Common Name:Project Panel 6mm AA Marine Grade Plywood

Growth Areas:Various

Properties:o “A” grade face and back so

superior face qualityo High strength and stiffnesses

Uses:o Structural

purposeso Laser cutting

Potential Health Risks:o Sensitiser

Botanical Name:Mixed hardwoods

Availability:Widely

Image Source- https://www.bunnings.com.au/project-panel-1220-x-810-x-6mm-aa-marine-grade-plywood_p0320037

SN- 31487307

Timbers- Carcass:

Common Name:Black Walnut

Growth Areas:Eastern United States

Properties:o Generally straight graino Generally easy to worko Glues wello Stains wello Finishes well

Uses:o Cabinetryo Flooringo Furnitureo Joinery

Potential Health Risks:o Sensitisero Irritant to eyes and skin

Botanical Name:Juglans nigra

Availability:Widely

Image Source- https://brittontimbers.com.au/timbers/american-black-walnut/

Timbers- Gears:Common Name:Brown Mallee Burl

Growth Areas:Southeastern Australia

Properties:o Extremely denseo Difficult to machineo Good finishingo Durable

Uses:o Turningo Small

speciality items

Potential Health Risks:o Sensitiser

Botanical Name:Eucalyptus dumosa or Eucalyptus viridis

Availability:Moderate

Image Source- https://www.wood-database.com/brown-mallee/

Timbers- Planets:Common Name:East Indian Rosewood

Growth Areas:India, Sri Lanka and Indonesian

Properties:o Usually interlocked graino Can be difficult to worko Good gluingo Good finishingo Rose-like scent

Uses:o Furnitureo Musical

Instrumentso Turningo Veneer

Potential Health Risks:o Sensitisero Irritant to skin

Botanical Name:Dalbergia latifolia

Availability:Widely

Image Source- https://www.wood-database.com/wp-content/uploads/east-indian-rosewood.jpg

Research of Components, Processes, Technologies, and Resources

7

Common Name:African Mahogany

Growth Areas:West Tropical Africa

Properties:o Straight to interlocked graino Easy to worko Easy to glueo Easy to finisho Tearout sometimes an issue

Uses:o Veneero Plywoodo Turningo Furnitureo Boatbuilding

Potential Health Risks:o Sensitisero Irritant to eyes and skin

Botanical Name:Khaya spp.

Availability:Widely

Image Source- https://www.cherokeewood.com/wp-content/uploads/2014/11/mahoganyAfricanPlywood.jpg

SN- 31487307

Common Name:Purpleheart

Growth Areas:Central and South America

Properties:o Usually straight graino Difficult to machineo Difficult to planeo Moderate dulling effect on

cutters

Uses:o Flooringo Furnitureo Turningo Speciality

items

Potential Health Risks:o Sensitisero Irritant to eyes and skino Can cause nauseaBotanical Name:

Peltogyne spp.Availability:Widely

Image Source- https://www.wood-database.com/purpleheart/

Common Name:African Padauk

Growth Areas:Central and Tropical West Africa

Properties:o Usually straight graino Easy to worko Tearout sometimes an issueo Turns, glues and finishes well

Uses:o Veneero Flooringo Turningo Furniture

Potential Health Risks:o Sensitisero Irritant to eyes, skin and

throatBotanical Name:Pterocarpus soyauxii

Availability:Widely

Image Source- https://www.wood-database.com/african-padauk/

Common Name:Zebrano/Zebrawood

Growth Areas:West Africa

Properties:o Wavy or interlocked graino Saws wello Difficult to planeo Glues and finishes well

Uses:o Veneero Furnitureo Turningo Boatbuilding

Potential Health Risks:o Sensitisero Irritant to eyes and skin

Botanical Name:Microberliniabrazzavillensis

Availability:Moderate

Image Source- https://www.wood-database.com/zebrawood/

Common Name:Poplar

Growth Areas:Eastern United States

Properties:o Straight, uniform grain o Easy to worko Very softo Glues and finishes well

Uses:o Furniture

frameso Plywoodo Veneero Turning

Potential Health Risks:o Sensitisero Irritant to eyes, skin and

throatBotanical Name:Liriodendron tulipifera

Availability:Widely

Image Source- https://www.wood-database.com/poplar/

Research of Components, Processes, Technologies, and Resources

8

Research of Components, Processes, Technologies, and ResourcesProcesses:

SN- 31487307

Process Where would it be used? Why? How?

Routing Routing would be used to create a moulding around the top and bottom plates.

Adding these mouldings would create a look similar to that of Bob Tiew’s Design. This more ornate detail also fits my desired aesthetic for the orrery.

With the desired router bit fitted, the piece of timber is slowly fed into the router bit in the same direction as the grain of the timber to prevent splitting. The timber is then pushed through the router bit against the guide until the whole length has been routed.

Process Where would it be used? Why? How?

Turning I would use turning to create the 6 planets that rotate around the sun. I would also use turning to make the crank handle.

I have experience turning spheres after my Year 11 project, meaning that turning would enable me to create the planets myself.

With the piece of timber secured between 2 centres or in a universal chuck, it can then be shaped using tools such as a bowl gouge, parting tool and skew chisel, or with sandpaper. To create the planets, a vague spherical shape will be turned within the block before the ball is cut out and turned between two cups to make the piece spherical. The rotation speed will be increased when each piece has been transferred to the cups to ensure a fine finish.

Process Where would it be used? Why? How?

Mitre Joints

Mitre joints would be used to join the 12 side panels together to create the dodecagonal shape.

Mitre joints would create a clean join and easily work with the required 30o angle

The mitre joints can either be cut by tilting the compound mitre saw to create the 30o angle, or by angling the blade of the table saw to 30o.

Process Where would it be used? Why? How?

Biscuit Joints

Biscuits joints would be used to join the two halves of the base plate together.

This will create a stronger join than a rub joint alone.

After identifying the necessary number of biscuits, a line will be drawn across the two halves and then the biscuit cutter will line up with those marks when cutting in order to make the pieces match up as desired.

Image Sources:Turning- http://www.getwoodworking.com/news/article/turning-for-beginners-part-3/924Mitre Joints- https://ottawacitizen.com/life/homes/house-works-four-tips-for-cutting-mitre-joints-like-a-proBiscuit Joints- https://www.woodcraft.com/blog_entries/biscuit-joining-basics 9

Research of Components, Processes, Technologies, and ResourcesTechnologies:

SN- 31487307

Technology Description How would it be used? WH&S Practices

Table Router A machine in which wood is fed along the table into a cutter attached to a vertically mounted spindle.

The table router would be used to cut the mouldings along the top and bottom plates.

o Teacher use onlyo Wear safety glasses and ear protectiono Wear hard-topped shoes and an aprono Never wear loose clothing or jewellery, and keep

sleeves rolled up and long hair tied backo Make sure work is fed against the direction of rotationo Feed work slowly into cutter

Technology Description How would it be used? WH&S Practices

Wood Lathe A machine which spins a piece at timber at varying speeds, allowing it to be symmetrically shaped with tools around the axis of rotation.

The lathe would be used to turn the 6 planets and the handle for the crank mechanism.

o Wear a face shield, hard-topped shoes and an aprono Never wear loose clothing or jewellery, and keep

sleeves rolled up and long hair tied backo Ensure the piece is securely fastenedo Rotate the piece by hand before turning ono Never leave the lathe running unattendedo Turn the machine off when making adjustments

Technology Description How would it be used? WH&S Practices:

Compound Mitre Saw

A machine which has the capabilities of both the circular and mitre saw; it can perform straight, bevel and mitre cuts.

The combination saw would be used to cut pieces of timber to length where necessary and to cut the 30o

mitre joints of the side panels

o Teacher use onlyo Wear safety glasses and ear protectiono Wear hard-topped shoes and an aprono Never wear loose clothing or jewellery, and keep

sleeves rolled up and long hair tied backo Keep supporting hand clear of the bladeo Wait for blade to stop spinning before removing worko Use clamps to hold piece still and secure

Technology Description How would it be used? WH&S Practices:

Table Saw A machine which has a blade protruding from the table surface that wood is fed into. Blade height and angle can be adjusted, and can cut a wide range of widths.

The table saw would be used to trim the width of pieces of timber and also could alternatively be used to cut the mitre joints

o Teacher use onlyo Wear safety glasses and ear protectiono Wear hard-topped shoes and an aprono Never wear loose clothing or jewellery, and keep

sleeves rolled up and long hair tied backo Use a push stick to guide timber througho Switch off and let stop before making adjustments

10

Research of Components, Processes, Technologies, and ResourcesTechnologies:

SN- 31487307

Technology Description How would it be used? WH&S Practices

Pedestal Drill A fixed machine that uses a variety of cutting bits to cut straight holes in timber.

The pedestal drill will be used to cut holes to house the brass rods where required.

o Wear face shield, hard-topped shoes and an aprono Never wear loose clothing or jewellery, and keep

sleeves rolled up and long hair tied backo Ensure work is securely fastened so it doesn’t spino Switch off and let stop before making adjustments or

removing swarf

Technology Description How would it be used? WH&S Practices

Dremel A handheld rotary multitool with a variety of attachments that can drill, grind, sharpen, cut, clean, polish, sand, route, carve and engrave.

The Dremel would be used to cut the brass rods and tubes to the correct length.

o Wear safety glasses, hard-topped shoes and an aprono Never wear loose clothing or jewellery, and keep

sleeves rolled up and long hair tied backo Turn off the Dremel and power at the outlet before

making any adjustments or changing accessorieso Do not used damaged accessorieso Be carful touching the accessories and material

immediately after use as the surfaces might be hot

Technology Description How would it be used? WH&S Practices:

Laser Cutter A machine which directs the output of a high power laser through optics to cut, engrave or etch a variety of materials.

I would use the laser cutter to cut the gears out of the burl wood and the other small components of the mechanism.

o Always use the exhaust systemo Do not look directly into the laser beamo Do not use highly flammable or explosive materialso Do not leave laser cutter operating unattendedo Do not use materials that have not been approved by

the manufacturer

Technology Description How would it be used? WH&S Practices:

3D Printer A machine which creates 3D objects by extruding a variety of materials layer by layer to create the desired shape.

The 3D printer will be used to create some sort of decorative piece in the gear assembly.

o Do not touch the nozzle or plate whilst hoto Do not use materials that have not been approved by

the manufacturero Use in a well-ventilated area with an exhaust system

11

Research of Components, Processes, Technologies, and ResourcesGlues:

SN- 31487307

Kleiberit PVA 305

Advantages Disadvantages

o High quality general purpose glue

o Water solubleo Dries clearo Non-toxic

o Loses strength over time

o Not super strong

3M Scotch-Weld Instant Adhesive CA8

Advantages Disadvantages

o Fast settingo Suitable for wood and

metal bondingo Strong bondo Dries clear

o Causes serious eye irritation

o Causes mild skin irritation

Purbond by Boatcraft

Advantages Disadvantages

o Strong bondo Expands so fills gapso Does not creep

o Expansion can create lots of clean-up

o Not water soluble

Finishes:Feast Watson Gloss Clear Varnish

Advantages Disadvantages

o Excellent protection against wear and scratches

o Self-levellingo Enhances the grain

o Oil-based so turps wash-up

o 8-hour recoat timeo Minimum 3 coats

Cabot’s Water Based Gloss Cabothane Clear Polyurethane Timber Varnish

Advantages Disadvantages

o Highly durableo Hard-wearingo 2-hour recoat timeo Easy clean-upo Only 2-3 coats required

o Does not enhance the grain

Sikkens Cetol TGL Gloss Plus Clear Timber Finish

Advantages Disadvantages

o Allows timber to breathe, expand and contract

o Highly durableo Only 2 coats needed

o Oil-based so turps wash-up

o 24-hour recoat time

Image Sources:Purbond-http://www.marinetimbers.com.au/uploads/images/IMG_0776.jpgFeast Watson Varnish- https://www.bunnings.com.au/feast-watson-1l-gloss-clear-varnish_p1520128Cabots Varnish- https://www.bunnings.com.au/cabot-s-1l-water-based-gloss-cabothane-clear-polyurethane-timber-varnish_p1522392Sikkens Finish- https://www.bunnings.com.au/sikkens-cetol-tgl-gloss-plus-1l-clear-timber-finish_p1522546Feast Watson Oil- https://www.bunnings.com.au/feast-watson-250ml-scandinavian-oil_p1564833

Feast Watson Scandinavian Oil

Advantages Disadvantages

o Highlights grain and natural colour

o Removes scratches and blemishes

o Only 1 coat needed, extra coats can build from a satin to gloss finish

o Oil-based so turps wash-up

o 12-hour drying time

12

Selection and Justification of Appropriate Materials, Processes and ResourcesTimbers:

SN- 31487307

For the carcass I decided to use Tasmanian Blackwood because I have always admired the colour and grain of this timber, particularly after seeing it used in one of last years major works on display at the SHAPE exhibition.

Tasmanian Blackwood’s properties also suit my needs perfectly, and although somewhat expensive I won’t need too much of it so it will remain within my budget.

For the gears I decided to try using the burl wood as I have some left over from a previous project that I can do some tests with. The existing designs of this orrery plan all use a light coloured plywood which whilst a perfectly suitable material is boring and aesthetically at odds to my design. Burl wood on the other hand has gorgeous grain that will mean that the mechanism as well as the carcass and planets is beautiful. The brown colour also complements the colour of Tasmanian Blackwood.

When choosing timber for my planets my only criteria was that they were suitable for turning, my primary focus was on choosing timbers which colour reflected those of the planets. With these parameters I selected East Indian Rosewood for Mercury, Mahogany for Venus, African Padauk for Mars, Zebrano for Jupiter and Poplar for Saturn. Earth ought to have been blue, however since there are no naturally blue timbers I decided to go with Purpleheart as I like the distinctive colour and felt that it was a fitting alternative for Earth.

Processes:By using the table router to route the mouldings I can complete them quickly and consistently. The mouldings will add the more ornate detail and aesthetic I am looking to establish.

Turning is the best process for creating the planets out of wood, particularly because I had prior experience turning spheres, and it will be the quickest way to get a sphere.

Mitre joints are the best joint to use to build the frames and attach them to create the dodecagon shape as these joins does not need to be particularly strong as they will have minimal stress on them. Mitre joints also look very clean and will work the best with the overall aesthetic.

Using a biscuit join for the base is the best option as it provides more strength than a standard butt widening without being overkill.

Technologies:Laser cutting will be the best tool to use to cut the gears as it is time efficient and exact which is important to ensuring that the mechanism will actually function. I can also use it to cut to top piece if I decide to do a design for that.

3D printing is another technology that I will use to create a decorative element for the gear assembly as I gained experience using it during prototyping for my pocket watch idea, and want to incorporate it into this project too. It also offers a backup way to make the gears if need be.

Glues:For glues I will use the Scotch-Weld and PVA glue. The PVA glue is the ideal glue to use for gluing up the carcass because it will provide the required strength to hold the frames together and glue the base to the frames, whilst being easy to apply, able to be cleaned up using water and drying clear.

I will use the Scotch-Weld to glue the rods onto the gears as it is an instant adhesive and suitable for gluing both metal and timber together which is exactly what I need.

Finishes:To finish the carcass I will use the Cabot’s Water Based Cabothane in a gloss finish. I selected this as it will have very good durability and the faster recoat time will be very important as I will likely be running short on time when I am lacquering the carcass.

To finish the gears I will use Feast Watson’s Scandinavian Oil as the main reason I choose the burl wood is because of how beautiful the grain is, and the Scandinavian Oil’s purpose is too enhance the grain so it perfectly suits my needs.

To finish the planets I will use the U-Beaut Polishes products EEE-Ultra Shine and Shellawax Cream as I have used these products in the past and was very happy with the quality of the finish they provided.

Resin:For the resin element of my design I will use Clariti – Ultra Clear Casting Resin from Barnes as I have had good experiences using this product in the past and therefore will use it for this project also.

13