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Three Wise Men Ornament
by
Barry GrossHandmade ornaments
have become a staple of your gift-giving repertoire ever since you started scroll
sawing. Does this sound familiar? Rather than another wooden fretwork ornament,
surprise your family and friends with this solid surface beauty featuring the
Three Wise Men as they follow the star to Bethlehem. The star is made from brass
and adds a bright accent to this classic scene. Consider using a brass insert
to jazz up your other holiday projects.
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Step 1
Place masking tape
on the solid surface material. This is done to dissipate some of the heat buildup
generated by cutting the solid surface material. You’ll also find it makes
removing the pattern easier when you have completed cutting the ornament. Use
3M Spray Mount Artist’s Adhesive to adhere the pattern to the masking
taped solid surface material. Place it diagonally to make the most of the material
used. |
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Step
2
Drill the blade
entry holes using a 1/16" bit. Also at this time drill the 5/32”-diameter
hole for the brass rod insert. |
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Step
3
Make sure the scroll
saw blade is exactly 90 degrees to your scroll saw table. This will aid in a
straight cut through the material. |
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Step
4
Round over the
back of the blade. Insert the #4 Artisan scroll saw blade into your scroll saw
and round over the back blade using a hone. This is done to reduce frictional
heat when making sharp turns in the solid surface material. |
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Step
5
Start cutting the
ornament with the inside cuts first. By starting with the inside first, it allows
you to hold onto a larger work piece. Use medium saw speed and do not push too
hard. If you do these things, you will get a clean cut as shown. |
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Step
6
Cut the remaining
inside cuts and cut around the star as shown. This is done to give added strength
for the next step. |
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Step 7
Insert the Metal Artisan #3
blade into your saw and cut a piece of the 5/32”-diameter brass rod to
3/8” in length. |
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Step
8
Place the ornament onto a piece of wax paper and take the 3/8” long
piece of brass rod you just cut and place it into the hole in the center
of the star. Now, drip a few drops of the thin CA glue over the brass
rod. The thin CA glue should now “wick” into and around the hole and in
a few minutes be a solid piece. |
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Step 9
Since you cut the
piece of rod slightly longer then the solid surface is thick, it should stick
out the back as illustrated. Use a sander of your choice and sand the back of
the star smooth removing the bump of brass rod. |
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Step 10
Cut the last of
the interior cuts being careful around the points of the star. |
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Step 11
If you want to
“clean up” any of your interior cuts, use a small metal file as
illustrated and clean up any saw marks that may be visible. |
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Step 12
Use 320 grit wet/dry
sandpaper and sand the outer and inner edges to smooth out any saw marks you
might have. Also use the small 2”x 2” sanding pads to polish the
inside edge of the ornament. |
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Step 13
Use the 5” sanding pads designed for solid surface and
polish the entire ornament to give it lasting shine. |
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Step 14
Don’t forget to sign
and date your ornament. All of my customers, friends and family want their mini
masterpiece to be signed, and yours will, too! |
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Tips
Cut Round Items Safely
Whether it’s a wooden dowel or a piece of brass rod, you can make
the job easier and safer by making this quick-and-easy jig. Simply cut
a groove in a piece of scrap wood to prevent the round object from rolling
as you cut it.
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 About
The Author
Barry contributes frequently
to Scroll Saw Workshop. His most recent articles were the “3D Unicorn”
(Spring 2004, Issue 14), “Aluminum Wall Sculptures” featuring geckos (Fall 2003,
Issue # 12) and the “Angelfish Sun Catcher” (Spring 2003, Issue #10). He just
completed a book for Fox Chapel Publishing on pen turning that was released in
September 2003 and already is in its second printing! He owns and operates BG
Artforms (www.bgartforms.com) in Bensalem, Pennsylvania. |
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Materials
- 1/4”
thick x 4 1/4” x 4 1/4” solid surface material
- 3M Spray
Mount Artist’s Adhesive, masking tape or packaging tape
- Hot Stuff
“thin” CA glue
- 5/32”-diameter
brass rod
- Sandpaper,
320 grit wet/dry
- 2”
x 2” aluminum oxide sanding pads
- 5”
8-hole aluminum oxide sanding pads
- Wax paper
- Jeweler’s
files
Tools
- # 4 Artisan
Blade scroll saw blade (AB#4)
- # 3 Metal
Artisan Scroll saw blade (MAB #3)
- Drill
with 1/16”- and 5/32”-diameter bits
- Random
orbital sander
Special
Sources
Special Artisan
Scroll Saw blades, the thin CA glue as well as the 5” solid surface
aluminum oxide sanding kit CSK-3 Corian Sanding kit is $17.95 and the
2” x 2” sanding pads (PFK-1) $13.95 are all available from
BG Artforms. To order, call toll free 888-717-4202 or visit
www.bgartforms.com.
Click Here To Download The Pattern
 To
view our patterns, simply click on the link above. You'll need the FREE
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below to get it now!
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Further Reading |
  Pen
Turner's Workbook
Buy Now |
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|
 Making
Noah's Ark & His 3-D Friends
Buy Now |
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