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1 StainlessSteelTravelMugLiner2 FinishedTravelMug

Travel Mug

Stainless Steel Travel Mug Instructions

TheTravelMugrequiresbothspindleturningandhollowingskills.Whilealotoftheinteriorwastecanberemovedbydrilling,youmustbeabletocompletetheinteriordiameteroftheblankusinglathechisels.You’llneedafaceplateorchuckformountingtheblanksoyoucanhollowinfromoneend(achuckissignificantlyeaisiertouse).Readthroughallinstructionsbeforestartingthisproject.

Becauseofthelargeblanksizethisprojectcallsfor,it’slikelyyou’llhavetogluematerialuptoachievetherequireddimensions.Youcandothisbygluingmaterialfacetofaceorbycreatingastaveassembly.

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MaTerIal lIST WxDxH WoodBlank 35⁄8"x35⁄8"x7" 27⁄8"ForstnerBit 21⁄8"ForstnerBit Tape Glue

Note: The finished mug shown was constructed using the stave construction medthod on page 2.

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Fig. 1

Face-To-Face ConstructionThisisagreatopportunitytousesmallpiecesofscrapandcreateauniquemugbyusingcontrastingwoods.Whenpreparingablankbygluingpiecesfacetofacebecertain,beforegluing,thateachgluesurfaceisdeadflat.Clampthematerialandallowittodryovernight.Fig. 1.Beforeturningthisblankusethebandsawortablesawtocutoffthecorners.

Stave ConstructionInordertogetthecorrectinsideandoutsidedimensionsforturningthemug,materialusedforstaveconstructionshouldbeatleast7/8"thick.

1.Eachoftheeightstaves,cutat22.5degrees,mustbe17⁄16"widefromlongpointtolongpoint.

2.Assembleeachhalfbylayingthestaves,longpointtolongpoint,onstripsofmaskingtape.Fig. 2.

3.Applygluetothejointsanduseadditionalmaskingtapetodrawthehalf-sectionclosed.Fig. 3 and 4.

Letthegluedry.

4.Aftertheglueisdryremovethemaskingtapeandtestthefinaltwojoints.Theyshouldcloseseamlessly.Fig. 5.Iftheydon’t,gentlysandthehalf-sectiononapieceofsandpaperlaidonthetablesaw.Fig. 6.

5.Oncethejointsclose,gluethetwohalf-sectionstogether.Fig. 7.

6.Aftertheglueisdryremovethemaskingtapeandcuteachendoftheblanksquareusingthemitersaw.

Fig. 2 Fig. 3

Fig. 4

Fig. 5 Fig. 6

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7.Cutapadofsolidwoodforeachend.Dothisbytracingtheoctagonalendontoaboardandcuttingtothelinesonthebandsaw.

8.GluethepadsontoeachendoftheblankusingCA(cyanoacrylate)glue.Fig. 8.

Getting Started-Faceplate1.Centerthefaceplateontheendof

theblankandsecureitwithscrews.Usesheetmetalscrews,whichhavedeepthreadsandwillgetagoodbiteontheblank.

2.Threadthefaceplateontotheheadstock.

3.Positionthelivecenteragainsttailstockendoftheblank.

4.Turntheblankround.

5.Carefullypartoffthepadonthetailstockendoftheblank.

Getting Started-Chuck1.Markoutcentersoneachendofthe

blank.Mountitbetweenthespurcenterandtailstock.Fig. 9.

2.Turntheblankround.Fig. 10.

3.Makeatenonontheheadstockendoftheblankthatwillfitintothejawsofyourchuck.Fig. 11.

4.Removetheblankfromthelathe,replacethespurcenterwiththechuck,andmounttheblankinthechuck.

Fig. 7 Fig. 8 Fig. 9

Fig. 10

Fig. 11

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Turning The Mug SleeveAnymaterialyoucandrilloutoftheblankwillsimplifythehollowingprocess.Thisstepiseasiestwith27⁄8"and21⁄8"Forstnerbits.Ifyoudon’thavethesebits,drillthelargestholeyoucanandhollowtherestwithalathechisel.

1. Mountthe27⁄8"Forstnerbitinadrillchuckinthetailstock.Becertaintoreducethespeedofthelathetoanrpmsuitableforthebit.

2. Bore11⁄4"intotheendoftheblank.Takeiteasyfeedingthebitin.Drillingendgrain,especiallywiththislargebit,buildsupheat.Excessheatcandestroyyourbitandyourblank.Fig. 12.

3. Switchtothe21⁄8"bit.Drillahole6"deepfromtheendoftheblank,43⁄4"beyondthebottomofthefirsthole.

4. Slidethetailstockoutoftheway.Younowhavetwoholes,stepped,insidetheblank.

5. Hollowtheblankby“connectingthedots”fromthestepatthebottomofthelargediameterholetothebottomofthe21⁄8"hole.Usearoundnosescraperorsimilarhollowingtool.Stopthelathefrequentlytocheckthefitbetweenthemuginsertandthehole.Theinsertmustslipinallthewayuptotherolledoverliponthemuginsert.

6. Whentheinsertslidesallthewayintotheblank,makeamark3/8"downfromtheendoftheblank.Useapartingtotoolcutarabbetuptothisline,makingalipthatwillfitundertherolledoverliponthemuginsert.Fig. 13.Beconservativewithyourcuts,doingfrequentfittests.Iftheinsertwon’tseatallthewayinmakecertainit’snotbeingrestrictedbytheholeinsidetheblankbeforeremovingtoomuchmaterialfromtherabbet.

7. Whentheinsertfullyseatsintotheblank,markoutthebottomoftheturning.Dothisbyaccuratelymeasuringthedepthoftheholeintheblank,add3/8",andplaceapartinglineontheblankatthispoint.Parttotheleftofthislinetodefinethebottomofthemug.

8. Useapartingtoolandcaliperstosettheoutsidediameterofthebaseofthemug.Setthecalipersto25⁄8".Fig. 14.

9. Shapetheoutsideoftheblank.Turnthetopsoittransitionsnicelyintothestainlesssteelinsertlip.Gentlytapertheblankfromtoptobottomandaddbeadsandcovesasyoulike.Beawareofthewallthicknesssoyoudon’tcutthrough.Fig. 15.

10.Sandandfinishtheturning.Polyurethaneisanexcellentchoiceoffinishforthisproject,asitholdsuptodampenvironments.

11.Parttheblankfromthelathe.

12.WithabeadofCAglueinsidethelipoftheinsert,pushthewoodenblankinplace.Fig. 21.Allowthegluetodry.

13. Onastaveconstructedblankyoucanleavetheholeinthebottomoftheblank,filltheholewithepoxy,orturnaplugtofillthehole.Onasolidblankyou’llhaveasolidbottomifyouaccuratelylocatedthepartinglocationinStep7.

Hardware to complete this project is available from Rockler Woodworking and Hardware. Call 1-800-279-4441 or visit www.rockler.com

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Fig. 15 Fig. 16Rev Rev05/12

Distributed by Rockler Companies, Inc. ©2012 Rockler Woodworking and Hardware

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