Help Sourcing A Tool

[Jerry Bruette]

I need some help sourcing a tool I need for a project.

I'd like to cut a bevel in a octagon shaped tube so I could glue in a 40mm acrylic ball.

The first picture below shows the tube and the second picture shows an attempt using a chamfering/deburring tool I borrowed from work. You can see some burning from the chamfering tool. Ideally the tool would be shaped like a sphere, but I can make a bevel work.

I think either a sanding tool or cutting tool would do the job.

Can anyone help me out?

440878440879

[Brian Tymchak]

I would be tempted to mount that on a lathe and cut the pocket with a round carbide cutter.

[Jerry Bruette]

I would be tempted to mount that on a lathe and cut the pocket with a round carbide cutter.

Me too if I had a lathe.

[Bruce Wrenn]

Me too if I had a lathe.


How about a circular template and router? Use a guide bushing and 45 degree bevel bit

[Jerry Bruette]

Would you be concerned with the bit blowing out the glued joints?

[Jim Matthews]

Me too if I had a lathe.

Do you have a drill press?

https://www.finewoodworking.com/2014/04/01/how-to-turn-pulls-without-a-lathe-2

[Bruce Wrenn]

Would you be concerned with the bit blowing out the glued joints?


No, the glue is stronger than the wood. You could take progessively deeper cuts till desired depth is reached

[Jerry Bruette]

Do you have a drill press?

https://www.finewoodworking.com/2014/04/01/how-to-turn-pulls-without-a-lathe-2

I used my drill press with the deburring tool I borrowed from work. It sorta worked but a similar tool costs about $160. That would definitely put me in the dog house.

Right now I'm experimenting with cutting angles on the ends of the pieces before gluing them together.

[Bill Dufour]

If the inner bore was the right size a rossette cutter might do it.
Bill D

[Dan Cameron]

I need some help sourcing a tool I need for a project.

I'd like to cut a bevel in a octagon shaped tube so I could glue in a 40mm acrylic ball.

The first picture below shows the tube and the second picture shows an attempt using a chamfering/deburring tool I borrowed from work. You can see some burning from the chamfering tool. Ideally the tool would be shaped like a sphere, but I can make a bevel work.

I think either a sanding tool or cutting tool would do the job.

Can anyone help me out?

440878440879

Jerry, I'd use a forstner bit or fly cutter to make a cylindrical inside shape. Then you could use a router with a bearing guided bevel or cove bit. Trick is to make a jig to VERY securly hold your octagon in place on the drill press.

[Bill Dufour]

A pipe internal taper reamer often goes to 2" diameter. the ridgid one is 15 degrees? I also have one to be used in a hand brace.
Bil lD

[Jerry Bruette]

Jerry, I'd use a forstner bit or fly cutter to make a cylindrical inside shape. Then you could use a router with a bearing guided bevel or cove bit. Trick is to make a jig to VERY securly hold your octagon in place on the drill press.

Ding Ding Ding

We have a winner. I drilled the end with a 1 1/2 inch forstner bit and everything fits perfect. Had the tool in the box the whole time, just had to noodle it out.

Just have to make the jig to hold it secure in the drill press.

For the curious folks, I want to make some teleidoscopes for Christmas presents.

[Steve Demuth]

If you have a lathe, then chuck it up and very carefully (end grain and all), cut the profile you need.

If you have a router, then make a circular template the right size, and use a chamfer bit.

If you have to make something, or are intimidated by the end-grain cutting involved in either of the above, take a solid piece of wood, chuck it in your drill press via a bolt through the center, and "turn" it with a rasp down to a 40mm cylinder, with a 45 degree or so cone at the bottom. Then super glue some coarse (probably 150 grit or maybe 80, but not something insanely coarse like 36 grit) sandpaper on the cone, and use the resulting tool to sand your chamfer into the piece. If you're really OCD about the fit, make the end of the tool you create a section of a sphere rather than a cone, and deal with the extra pain of gluing the sandpaper onto that compared to the cone (which is at least flat in one surface dimension).

Edited to add: Oops - hadn't read the whole thread. Obviously this is redundant at this point.

[Dan Cameron]

Jerryy. here's an idea for that jig. Take two pieces of scrap 2x6, p;y, or whatever just slightly longer than your tube. Make a "L" shape. Drill a hole in each side that will allow you to clamp the tube on the inside corner in two directions. Then the "L" can be double clamped on the drill press table. After drilling, you could use that same jig to stabilize the routing operation.

[Bradley Gray]

googled 40mm profile sander, found this:
(https://www.rockler.com/inflatable-bowl-sander?country=US&sid=V91040&promo=shopping&utm_source=google&utm_medium=cpc&utm_term=&utm_content=pla&utm_campaign=PL&tid=pla&gclid=EAIaIQobChMIspGUk7nk6wIVkcDACh16cQr-EAQYAiABEgJ9OvD_BwE)

https://www.rockler.com/inflatable-bowl-sander?country=US&sid=V91040&promo=shopping&utm_source=google&utm_medium=cpc&utm_term=&utm_content=pla&utm_campaign=PL&tid=pla&gclid=EAIaIQobChMIspGUk7nk6wIVkcDACh16cQr-EAQYAiABEgJ9OvD_BwE


(https://www.rockler.com/inflatable-bowl-sander?country=US&sid=V91040&promo=shopping&utm_source=google&utm_medium=cpc&utm_term=&utm_content=pla&utm_campaign=PL&tid=pla&gclid=EAIaIQobChMIspGUk7nk6wIVkcDACh16cQr-EAQYAiABEgJ9OvD_BwE)

[Jerry Bruette]

Jerryy. here's an idea for that jig. Take two pieces of scrap 2x6, p;y, or whatever just slightly longer than your tube. Make a "L" shape. Drill a hole in each side that will allow you to clamp the tube on the inside corner in two directions. Then the "L" can be double clamped on the drill press table. After drilling, you could use that same jig to stabilize the routing operation.

Pretty much what I was visualizing. I have some scraps of birch ply and mdf to use.

[Jerry Bruette]

googled 40mm profile sander, found this:
(https://www.rockler.com/inflatable-bowl-sander?country=US&sid=V91040&promo=shopping&utm_source=google&utm_medium=cpc&utm_term=&utm_content=pla&utm_campaign=PL&tid=pla&gclid=EAIaIQobChMIspGUk7nk6wIVkcDACh16cQr-EAQYAiABEgJ9OvD_BwE)

https://www.rockler.com/inflatable-bowl-sander?country=US&sid=V91040&promo=shopping&utm_source=google&utm_medium=cpc&utm_term=&utm_content=pla&utm_campaign=PL&tid=pla&gclid=EAIaIQobChMIspGUk7nk6wIVkcDACh16cQr-EAQYAiABEgJ9OvD_BwE


(https://www.rockler.com/inflatable-bowl-sander?country=US&sid=V91040&promo=shopping&utm_source=google&utm_medium=cpc&utm_term=&utm_content=pla&utm_campaign=PL&tid=pla&gclid=EAIaIQobChMIspGUk7nk6wIVkcDACh16cQr-EAQYAiABEgJ9OvD_BwE)

Never thought to call it a profile sander. Looks like it would work too.