Turning bottle stopper without the dowel breaking.

So you setup a blank or two with the dowel glued up like you read about and put the dowel end into your Jacobs or drill chuck only to have the dowel snap while truing the blank. It can easily happen even with tailstock support. Frustrating eh? The torque of the rough cuts is simply too much for the dowel. My first project as a turner seven years ago was bottle stoppers and it was not easy. I tried it with the dowel preglued only to have it snap during roughing out. I tried a pin chuck only to have it loosen up constantly, then the pin falls into the sawdust and vanishes. Nothing seemed to work reliably. Then I saw the light and figured it out.

This is what you need to turn bottlestoppers with minimal problems, some steel rod the same diameter as the dowel (any Hardware store) and a four or three jaw scroll chuck. I do not recommend using a Jacobs or drill chuck since these typically are not safe without tailstock support. Additionally, I need the dowel to travel through the body of the chuck and into the spindle. You'll see why later. You also will need an uncut length of dowel from any hardware store, predrilled corks (any woodturning vendor sells them), a small blank of nice colored wood and some glue.

Start by cutting the length of rod to about four inches in length, then grind the end so it has a sharp prong to bite the blank. Drill your blank about an inch deep. Put the rod into your chuck, slide the blank onto the rod and then use a small piece of wood between your live center spur and the blank when you bring up the tailstock. This way you don't get the small hole bit into the top of your blank. A small piece of larger dowel or a preturned plug works fine. Crank the tailstock a bit to get the rod to bite the inside of the blank and rough out the shape. If the blank is end grain along the axis of the lathe, be careful. You can easily split the blank if there is too much pressure. While roughing and shaping I use my parting tool for flattening the blank's bottom, this ensures a nice even seat to the cork. After I get my shape on all but the point touching the wood at the tailstock I remove the blank. I then glue the blank onto the end of the length of dowel. No, I do NOT cut the dowel then glue. Instead I cut the dowel last this way I get the most out of the length of dowel. After it's nice and secure I then slide the dowel into the chuck. Make sure you put the dowel all the way through so that the blank sits flush against the chuck 's jaws. This makes it much more secure and minimizes vibration. I then finish shaping the top of the stopper. Then I move the stopper out of the chuck a bit and retighten so I can sand and finish the entire stopper. Lastly I remove the stopper and the length of dowel from the chuck glue on the cork and cut the dowel flush at the bandsaw. I then use the rest of the dowel for the next stopper. No more broken dowel. No need to buy a special chuck. Happy turning!

Reply to
<ace
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I just started turning bottle stoppers, but rather than using a dowel I just turn down the bottom of the bottle stopper to the required thickness and insert it into the cork. This saves a lot of time and is easier than drilling out the stopper to insert the dowel.

Reply to
Ralph Fedorak

hmmm...I see how the steel rod would help, but I never though of that, so I learned to turn stoppers by just being careful... The most important point was what you noted about being sure the blank is flat and flush with the chuck, but I also did my roughing and shaping with tailstock in place and using the sharp point of a skew to reduce the impact and shock to the blank. (I even resorted to using a sharpened awl or ice pick for small areas or elaborate shapes!)

I also did all my drilling and holding with the #1 jaws of a Oneway chuck, instead of a Jacobs chuck, which gave me pretty solid 4 jaw support. If one already has something like this, I would recommend it, as it has a bit larger surface area for the base of the blank.

I do like the idea of the temporary support of the metal dowel for some projects...thanks.

Reply to
Bill Day

Nova pin jaws for me. Lots of long, not much thick. That, and not forcing the cuts, seems fine.

Reply to
George

Ralph, Thanks for a really innovative method. I'm gonna try it, but I've got to use up all my pre-cut blanks first. :) Wasting expensive stock to make the dowel/tenon might be a problem for some, but not for a roadkill wood cheapy like me.

Ace, you might want to consider some thingamajigs that I have made & used, tho actually a pin chuck works well for me.

  1. remove the head from a coarse thread bolt a small size up from 3/8 in. hold it in a Jacobs chuck secured with a drawbar. (many Jacobs chucks & centers have a hole in the taper's end already threaded for threaded rod) cut the rod to fit the lathe spindle's length and secure with a washer and wing nut every turning shop needs a draw bolt ;) screw the drilled blank onto the secured bolt and turn

2, drill a shallow 5/16 in. hole in the end of a 3/8 bolt or rod and grind the edges to make a multi tooth spur drive on the end hold in a Jacobs chuck secured with a drawbolt tap the blank firmly onto the rod and turn

  1. a variation is to scar one face of a nut that fits the bolt hold the bolt in a Jacobs chuck/drawbar and run the nut up to the chuck jaws, scarface out. ie. a horrible melange of a spur drive on the end of a combination of a long screw chuck/counterbore drive with a scarred face. :) Who's on first?

  1. finally, carefully place rods, bolts and nuts in your garbage can and get out a small pin chuck and lots of cut off nails as replaceable pins Arch

Fortiter,

Reply to
Arch

I just cut a length of 3/8 steel rod and ground a flat on it - instant pin chuck. Works great for stoppers, although I hold in in the machinist's jaws, not the supernova. I suppose one could make a suitable wooden holder for it ;-)

Reply to
DJ Delorie

To me, this seems a bit involved: you can use a 3/8 steel rod (the usual diameter of the holes in pre-bored corks), drill a 3/8 hole in your blank, squirt in a bit of water, shake the water out and jam the blank on the rod: no tailstock support necessary in my experience. I leave the stopper chuked this way thru sanding and finishing with Hut, then pull off and glue in the dowel.

Kip Powers Rogers, AR

Reply to
Kip055

Have you tried a maple dowel rather than the softer pine dowels sold in hardware stores?

Bob, Naugatuck Ct.

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Reply to
Bob Pritchard

What I do is use a 3/8 forstner bit preset set to dill into my prospective blank about 3/4 of an inch. Then mount the blank onto a set screw secured by my SuperNova chuck and turn it. Never had a single problem and I've turned about 200 so far. With a 3/8 dowel I press into the finished blank with a C- clamp and glue with yellow glue. Attach the cork and Viola!...You are done... I've got it down to about 8 minutes to completion once I drill the initial hole

moyo

Reply to
moyo

Seems to be a dozen ways to skin a cat. Here's mine:

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'later...

...Kevin

Reply to
Kevin & Theresa Miller

Arch, I use scraps for bottle stoppers so the wood pieces I use are on their way to the fireplace.

Reply to
Ralph Fedorak

I sell 3/8 pin chucks for $7.50 (milled flat) which includes postage in the US. I mount my pin chuck on a 2" thick waste block mounted on a spare faceplate. Turn the waste block round and drill a 3/8 hole in the center. Dab of 5 minute epoxy in the hole and insert the end of the pin chuck.

One of the advantages of a pin chuck beside not breaking dowels and ruining the blank is you can finish the stoppers in bulk and store until you are nearly ready to sell. Add the dowels and corks at the last minute. Keeps the unsold cort and dowel inventory to a minimum.

Doug Turner

Reply to
Doug Turner

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