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Thread: Making a Federal Style fan

  1. #1
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    Making a Federal Style fan

    Iím in the process of making a Federal Style table and needed a traditional fan inlay. Thought about buying one from a supplier, but really?, buy one? So I ventured into new territory. As it turns out, itís not difficult, and quite fun to do. For the price of a bag of sand and a little veneer, it was a fun project.

    For those interested, hereís the process I used:

    First a template is made with segments measured out:

    57731F41-6781-47E6-B448-E7F10EB9C0CE.jpg

    Then a bunch of small squares of veneer are cut. Given this was my first time, I decided to make a few and experiment with maple and birch.

    Once the squares are made, a skillet of sand is heated to high. I found just a 1/4Ē of sand is best, otherwise the entire piece gets charred vs just the edge.

    8FF527AC-932D-4208-9916-4FA5FDAD0BCB.jpg 885C9550-3134-4A6D-A38E-BF1B51083144.jpg

    The template is then transferred to a ďcutting boardĒ and segments are cut using the segment lines with a plane iron.

    F5AD5A9E-680C-4761-8F78-C1313FEB960E.jpg

    These are then assembled onto a piece of veneer tape.

    C00017E7-B1E8-4034-9580-8792366C764C.jpg DEE06A2F-AD4A-4BE7-AEB0-39F1491F2758.jpg

  2. #2
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    Then the template is used to trace the pattern onto the veneer segments.

    15FFEF85-BEEF-42D7-A9B0-43F8A55BC23D.jpg

    A carving gouge is then used to cut out the scallops around the outside of the segments.

    105CD8DC-BDD4-48E7-8253-D495846084BA.jpg B54AD7B6-9D7F-4A90-8037-20125277AA65.jpg

    Using the same gouge, sections of black veneer are cut and taped into place using veneer tape.

    CCF97BEF-02BA-4D6A-89CC-E39ABB444E09.jpg

    A different, smaller radius gouge is used to cut out the center piece, and a piece of black veneer is taped in place.

    6A73B0D3-E829-4C7B-A017-79FB30753D49.jpg
    Attached Images Attached Images
    Last edited by Phil Mueller; 03-15-2020 at 7:14 AM.

  3. #3
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    Then the entire thing is glued to a piece of veneer. I also glued it to a second 1/16” piece of veneer to give it more stability while working on it.

    CCE06977-7D90-4607-B1D3-ADB4B4467026.jpg

    They were cut apart, and then using the template, the pattern was again transferred to the piece and cut out using a fret saw, and refined with a riffler and file.

    B052AEC7-191A-4171-A056-EADA72B8F0AB.jpg


    I wanted to outline the fan with a piece of stringing. I pre-bend these by soaking in hot water, and then wrapping it around a piece of PVC.

    45C65B41-8B52-4D15-AE21-93BB718D9F08.jpg

    The stringing is then cut, glued and taped until dry.

    3D475FAB-0236-4326-8127-D58026A6BBE0.jpg

    After a little light sanding, they are ready to be inlayed.

    9C77E7A1-8885-4AF5-8ECA-1D6CF2D83EAE.jpg

    I’m glad I made a few...you’ll notice a couple with uneven segments, and the shading seems better on some.
    Last edited by Phil Mueller; 03-15-2020 at 1:49 PM.

  4. #4
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    phil thanks for posting how you did that. ive alway been afraid of making banding and marquetry but that looks very doable jerry

  5. #5
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    Very interesting post Phil. I’m not seeing the photos of the last post. Not sure what is up with that. The fan looks great.

  6. #6
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    Not sure whatís up with the photos on the last post either. Tried editing, but couldnít get it to change. Hopefully a Moderator will come along and fix it for me.

  7. #7
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    Phil,Is the charring in the sand just for asthetics, or does it make it easier to cut the wood?

    And are the tapered edges of the veneer glued together?

    Thanks for posting this. I may try it in the future.

  8. #8
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    I have been getting the same troubles with photos I tried to post yesterday....had to go back and re-size all the "bad" photos down to the size of a Postage stamp....THEN they showed up

  9. #9
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    Good call Steven. Thanks. Resized, and now showing.

    Michael, the charring (or shading as itís called) is to give the pieces a more 3D look. Itís meant to be a shadow line against the adjoining piece.

  10. #10
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    Nice demonstration Phil! Good to see handwork in Neanderthal land

  11. #11
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    Great post Phil and looking forward to more on this project.

    The 3D effect from the shading and scalloped fan blades is fantastic.

    jtk

    -pun wan't intended but was fun to realize.
    "A pessimist sees the difficulty in every opportunity; an optimist sees the opportunity in every difficulty."
    - Sir Winston Churchill (1874-1965)

  12. #12
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    They came out really nice. Thanks Phil.

  13. #13
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    Hi Phil,

    Those are impressive, especially the sand shading. I also like the black bordering, which really makes the fan pop. How thick is your veneer?
    "You can observe a lot just by watching."
    --Yogi Berra

  14. #14
    Quote Originally Posted by Phil Mueller View Post
    Not sure what’s up with the photos on the last post either. Tried editing, but couldn’t get it to change. Hopefully a Moderator will come along and fix it for me.
    Which post specifically and what needs to be fixed?
    Lee Schierer
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    Captain USNR(Ret)

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  15. #15
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    Hi Lee, thanks. It was the third post, but after resizing, they loaded fine.

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