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Hollow form turning basics

written by Chris Wright
 

This is a basic outline of turning hollow forms. Keep in mind that turning hollow forms takes quite a bit of practice to develop the feel for the tools, the sound the wood makes as the walls thin and learning to extend your sense of form in the reverse to keep the wall thickness even. Although a good pair of calipers will help with the last one. The rule of 3 definitely applies to hollow forms as a bad form will ruin the best turned piece. I tend to prefer forms with high shoulders and small feet, resembling an egg standing on it's point. This is also one of the more difficult forms to achieve. When starting out with hollow forms it is a good idea to begin by turning an open form such as a small bowl with the tool so you can see the cutting action of the tool while getting the feel for it. Once you get into more closed forms you will have to rely on feel as many times you won't be able to see around the tool into the form. Since you can't see inside the form when turning them, I chose to use photos of a form I am turning with line drawings superimposed over the photo to illustrate the inside action of turning hollow forms. Let's get started....

 
 

Here is a view of the tools I normally use on various small hollow forms. Notice the markings and/or grub screws line up with the centerline of the bit. This is so when I have the tool inside a hollow form I can tell how much of an angle I have at the cutting edge and helps to avoid bringing the tip above center. This is especially important on the right angle tools where you turn the tip up into the cut. For this form, I mainly used the 3/8" set on the left, but I also used the right angle 1/4" tool (far right) to help shape the inside of the upper shoulder).


click photo to enlarge

I start by turning the form between centers using a safety center (also known as a dead cup center). I turn the form as close to final form as possible before moving it to the chuck. This allows me to rough and tweek the design without having to worry about working around the chuck and I can adjust the spigot size as the form changes shape or shrinks due to working around checks and such easily. I also turn the piece so that the tenon is at the headstock side so I am not flipping the piece around to mount in the chuck. You stand a better chance of it running true after the transition doing it this way.

Once the desired form is achieved, mount in the chuck and remove the remnant of the tailstock end. True the form up and make your final cut on the outside. Notice the large section I left at the foot section for strength during hollowing. This will be trimmed up later to fit the form. At this point, I sand the outside to 400 grit. This will eliminate the need to sand as much later which could put undue pressure on the hollowed form and possibly break it.


click photo to enlarge
Next, use a spindle gouge to mark the center of the form. Then use a depth drill determine the depth of the piece, remembering that you will be trimming up the bottom. I leave an extra 1/8" at the bottom for a tad extra weight and stability. Drill the center out of the piece to depth. This will help you determine when to stop at the correct depth and it also removes the "core" of the piece which is the most difficult part to hollow.

click photo to enlarge
When first starting out, you'll probably want to make the opening quite a bit larger than the diameter of the tool to give yourself room to move around inside. Later as you feel more comfortable, make the opening progressively smaller until you are working with an opening only a 1/4" larger than the tool diameter. In this case I am working with a set of 3/8" diameter tools so the hole is 1/2"...1/8" larger than the tool.
click photo to enlarge

The next photo illustrates many of the points outlined above as well as those to come...just thought I'd mention it. You can see here the meatier foot section left for strength while hollowing. The depth is drilled (blue lines) and from there we would start by opening up the top area with a straight bit tool. Once the inside is opened up enough, we can start using a angled tool to work the top and transition into the shoulders. Make sure to go down to your desired thickness about an inch at a time, opening up a bit more, thinning the wall, then opening up again. Take wall thickness readings with your calipers often to make sure you don't accidentally cut through the wall and end up with a bowl. The reason for this progression is once a form has a thin enough wall you cannot go back. If you attempt to go behind where you last cut to true up a bump or something your risk of ripping the section behind the cut dramatically increases as there will not be enough wall to withstand the bite of the hollowing bit. Progress down the form (black lines) until you reach the depth you drilled earlier.


click photo to enlarge


Here's a bit about tool angle. By the photo to the right, you'll see that you want to keep the tool angled down, but with the tip at the center line. This will mean adjusting the tool rest up a bit. The angle doesn't have to be steep at all, just a slight downward angle. Also, keep the cutting edge of the tip at the center line. If you go above center line you run the risk of a bad catch. When cutting above center a catch will send the tool deeper into the piece. Cutting at center will throw the tip into open space below and avoid complicating the catch and make it easier to recover and keep turning. You'll need a compressor or a can of compressed air to help clear the shavings. If neither is available, a coat hanger straightened out with a small hook at the end also makes a good tool to pull the shavings out.

 



click photo to enlarge

It is important to stop and clear the shavings regularly. The shavings can bind around the bit and cause it not to cut properly as well as cause it to jam and possibly pull it out of your hands...a bad situation. So take the time to clear them out. I usually take a caliper reading at the same time since the lathe is off anyway and kill two birds with one stone. You can see in the picture to the right that the shavings build up pretty quickly.

click photo to enlarge

After the shavings are cleared from the inside, take a minute to check the thickness and finish on the inside. With a opening this small, it is more important that good tool control is used to obtain a nice even finish on the inside as you can not get sanding materials in there easily. Using calipers or bent wire to check thickness, make sure the wall thickness is as even as possible throughout. This will affect the feel of the piece once it's finished; form as well as balance is important as people will want to pick these up and no matter how good the form, an unbalanced piece can change someone's mind about whether they like it or not.


click photo to enlarge

With the hollowing complete, now is the time to attach the collar (if you plan to have one). This was a collar I had made previously from Honduran Rosewood. In case I haven't mentioned it before, the hollow form is Silver Maple. I use clear epoxy to attach my collars because the working time is longer, the bond is flexible and will move with the piece over time and it doesn't seep into the wood and discolor the piece. Notice I took the entire assembly off the lathe to work on it. This also allows me to work on other small turning projects while the epoxy is drying.
click photo to enlarge
With the collar dry and the form mounted back on the lathe, here comes the scary part. With a LIGHT touch, turn the collar to flow with the form of the vessel. The reason I say light touch and cuts is if you were really good in your hollowing and the walls are thin, one catch will blow the entire thing to pieces. Make sure the gouge or skew you use is sharp and take planned deliberate cuts and you should be fine.
click photo to enlarge
Now the next scary part...note: these are only scary the first time or two you do them. If you plan out the form well, there isn't much need to worry, you should have plenty of room to work. In this step, cut the meaty part at the foot we left to hollow the form. Complete the curve and create the foot (or lack of one) and finish the form. As you get closer to finished form, take light cuts and check the thickness often to make sure you don't cut through the sides. With the collar attached, it may be difficult to use calipers, so try knocking lightly on the sides with your fingernail or something else soft enough not to dent the piece and listen for a consistent "hollow" sound. Where the piece is thicker the sound will be lower pitched.
click photo to enlarge
Earlier we sanded to 400 grit to make things easier for this point in the project. With the form finished, the collar attached, etc. Now is the time to re-sand the piece to blend the foot area in and bring it to the final grit, in this case, 1000. I like to sand everything again to make sure all of the edges, new and old cuts and such blend nicely. Notice I keep one hand under the form to support it against my upper hand which is applying a little pressure while sanding. We wouldn't want to break the piece off just yet.
click photo to enlarge
The piece is sanded and ready for finishing. For small (under 4" dia.) pieces I use French Polish or Friction Polish to finish the piece. Normall 3-4 coats burnished in look great. Here you can also see that I have cut the tenon back and made the "foot" a bit smaller so the finish can be applied over as much of the form at one time as possible.
click photo to enlarge
After you have applied your finish (should you also decide to apply it on the lathe like I did), it is time to part the piece off of the waste. I have a small 1/16" parting tool that I bring right up against the foot and part off as much as possible. Angle the parting tool in slightly to create a concave area to the foot, this will help it sit right even if the piece moves alittle bit later. Once off of the lathe, you may have a tiny bit of waste left. Use a carving knife to cut it away and sand smooth. Sign the piece and apply finish to the foot area.
click photo to enlarge
A photo of the finished piece. Now go ahead and try your own. Enjoy!
click photo to enlarge
 
     

 


 

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