ROLLING PIN INSTRUCTIONS

 

CUT LIST :  BARREL – 2-1/2 to 3-1/2” square x 10 to 16” long; HANDLES –1-1/2 to 2” square x 5” long; PINS -- 1” square x 6-1/2” long

 

Note:  Pin blanks need to be 1-1/2” longer than handle blanks (i.e. 4” handle, 5-1/2” pin).  Barrels lose 1/2” in length.  Handles finish at 4”, pins at 5-1/2.”

 

The size and shape of the handles will be something to experiment with, but they should be in proportion to the barrel.

 

You need to make two jam chucks with tenons: one with a 1/2” tenon 3/4" to 1” long, and one with a 5/8” tenon 3/4” to 1” long.  If your lathe chuck cannot be closed down to 1/2” you will also need a third jam chuck with a 1/2” hole drilled 1” to 1-1/2” deep. Choose an overall size of the chuck blanks based on the capacity of your adjustable chuck.

 

THE BARREL

 

  1. Mount the barrel blank between centers, start roughing from one end to the other, removing the corners.

 

  1. Using calipers and a parting tool* cut down to the maximum size the blank can be.  Make several of these cuts along the barrel (the more the better).  Use a skew to cut down almost to the bottom of these cuts.  This will leave enough stock to correct for trueness after drilling the holes for the handle pins.  *(Be sure that your parting tool cuts a groove wider than the width of your calipers. If not, the calipers won’t reach bottom and/or can be ripped violently from your hands.  I’m talking from experience here!)

 

  1. Using a skew, make a peeling cut to form a tenon on both ends of the blank that will fit your chuck.

 

  1. Remove the barrel blank, but while you have the centers installed on the lathe, rough out the jam chucks. Each will be finished when we need them.  Round the blanks and put a tenon on one end to fit your chuck.  Do this on all three pieces.

 

  1. Install your chuck and mount the barrel in the chuck, using the tailstock to help align the barrel.  Before drilling the barrel, remove the indentations made by the centers (unless they are small enough to satisfy the drill tip).  The end should be flat or slightly convex.  Avoid drilling into the hole made by the centers, because if the point of the drill bit is not able to guide the bit, the cutting edge engages first and the hole will be larger than desired.  Once this hole is removed use a skew tip to make a new guide hole for the drill tip.  Install a 1/2” Brad Point or Forstner bit in a Jacobs chuck and drill to a depth of 1-9/16” plus the length of the tenon.  After drilling, remove the Jacobs, install the cone center in the tail stock and check that the tenon is still centered.  If not, true it up.

                                                              

  1. Remove the barrel and flip end to end, in preparation for drilling.  But first, remove the tailstock tenon, which is no longer needed.  Repeat the drilling instructions above (but this time you want the end flat and square to the barrel).

 

  1. Install one of the jam chucks roughed out earlier into your chuck to make a 1/2” tenon 3/4” – 1” long.  Start with a skew and make a peeling cut to about 3/4” diameter.  Then use a parting tool and calipers to measure and cut to the desired 1/2” diameter.  Do this in a couple of spots.  Use your skew and cut down close to the final size, using the barrel to check the fit.  When complete, mount the barrel on the jam chuck, and use the cone center in the tailstock to help keep the barrel concentric.

 

  1. Use a skew to remove the remaining tenon, making the end flat and square to the barrel.  Turn the barrel to its finished diameter.  Use a straight skew or a square chisel to remove any ridges.  With the lathe off, check the barrel for uniformity using a straightedge, and then rework the surface to remove any deviations.   (If you check the barrel with the straightedge while the lathe is on, it will mark the deficiencies in the turning, but caution must be used!)

 

  1. Sand the barrel to 400 grit.  It is a good idea to wet sand the last couple of grit sizes.  If you’re not wet sanding, at least wipe down the barrel with a wet cloth after 320 grit, giving it a couple of minutes for the grain to raise, then finishing with 400 grit.  (With the lathe off, check for grooves and/or scratches.  It may be necessary to sand parallel to the barrel to remove these.)

 

THE HANDLES

 

  1. Mount a blank between centers, and rough it to round.

 

  1. Using a skew, cut a tenon on both ends to fit your chuck.  If you can drill straight through on Step #5 you only need to cut a tenon on one end.  Remove the blank.

 

  1. Mount the second roughed jam chuck and use the procedure from Step #7 above to make a 5/8” tenon on one end.  Remove the jam chuck.

 

  1. Install and mount the blank in your chuck, using the tail center for alignment.  Remove the tail center, true the end and use the skew point to mark the hole for the drill tip.

 

  1. Use a 5/8” Forstner or Brad Point bit to drill through the blank.  If you drilled through both ends part the handle off as close to the chuck as possible.

 

  1. Install the 5/8” jam chuck and the cone center; remount the blank with the tenon at the tail end.

 

  1. Turn the handle to the shape you choose.  (You can do away with the tenon by incorporating it into the handle design).

 

  1. Remove the cone center and true up the end.  Sand and wax the end with paraffin.

 

  1. Flip the blank and repeat Step #8.

 

  1. Mount the second blank and duplicate the completed handle.

 

THE PINS

 

  1. Mount the blank using the chuck and tailstock.

 

  1. Turn the blank round.

 

  1. Using a parting tool and calipers make a cut at the tail end, and another 1-1/2” towards the head to 1/2” diameter.  Turn the area between these cuts to 1/2” diameter.

 

  1. Repeat, but make a 5/8” cut next to where the 1/2'” cut ended, and another 5/8” cut 4-9/16” away.  Turn the area between to 5/8.”

 

  1. Check that the pin fits the handle and barrel.  Adjust if necessary.

 

  1. Sand and wax the 5/8” diameter section only!  Do not wax the 1/2” section or the glue will not adhere.

 

  1. Install the last roughed jam chuck and drill a 1/2” hole 1” deep.  If your chuck can close down enough to hold a 1/2” diameter pin you can omit this step. 

 

  1. Insert the 1/2” end of the pin blank into the jam chuck and shape and sand the head to your liking.  

 

  1. Mount the second pin blank and duplicate the first.

 

ASSEMBLY

 

Apply epoxy or wood glue (my choice would be waterproof Titebond III) only to the 1/2'” end of the pin after sliding the handle on, and insert into the barrel.  Twist to spread the glue.  Repeat on the other handle assembly.  (The pin should be tight enough so no clamping is necessary.)

 

Although no finish is necessary, be sure your choice is food-safe.  Wash by hand only.  A little salad oil will protect it well.