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Discussion Starter · #1 ·
Hello all.

I'm making a flag display box for my grandfather who recently passed away at the ripe age of 97. He served in the Navy during WWII. So, this build means a lot to me and is very timely over this Memorial Day weekend (ain't just about bbqs and whatnot).

I'm pretty much following Tommy MacDonald's flag box build that he did for Rough Cut. Part of the build is clamping the sides after mitering them. He achieve the clamp on the 22.5 + 22.5 degree joint by gluing the cutoffs from the sides to the outside of the sides, giving you two parallel surfaces for gluing. Then, you saw off the cauls and plane flat.



The front page of Pop Woodworking has a turning tip for turning half columns. That is to glue up to pieces of wood with paper bag sandwiched between them and use that glue line as the center mark of your turning. When the column is turned, you can easily split the column down the centerline.

Is this a valid strategy to make the caul removal easier for my flag box? Or should I not try this. I would hate to have to scrap my work due to a screw up either way.

Thank you all for making it through a long post and for any thoughts on this you might have.
 

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It's a great method

If you can successfully remove the "cauls" by planing, chiseling and sanding there is no downside. The paper trick is age old for turners who need a back plate to hold their workpiece in the chuck. It usually just pops off cleanly with a chisel in the joint. :thumbsup:
 

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As long as the frame is made of a fairly hard wood it should work just fine. Personally, that trick scares me. But plenty of people have success with it all the time. Just make sure to break or chisel it apart on the waste side then pare and/or sand the paper away.
 

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Discussion Starter · #5 ·
Well, my bourbon is normally put in a paper bag, so I should be able to acquire one with some Blanton's or Beam.

Thanks for chiming in everyone. The wood is cherry.

If anyone else has experience or want to toss out a tip to a newbie, I'd sure appreciate it. Even alternate clamping methods. I fear cutting the frame when sawing off the cauls, and fear denting the frame as I pry off the "paper bag" cauls.
 

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there are other "temporary" means

For instance a dab of hot glue, a strip of double sided tape etc...
try some experiments to see which works best with your wood and doesn't leave a mark or remove fibers. :yes:
 

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The front page of Pop Woodworking has a turning tip for turning half columns. That is to glue up to pieces of wood with paper bag sandwiched between them and use that glue line as the center mark of your turning. When the column is turned, you can easily split the column down the centerline.

Is this a valid strategy to make the caul removal easier for my flag box? Or should I not try this. I would hate to have to scrap my work due to a screw up either way.
Wood turners call this a "paper joint". Very strong.

One use is to glue a bowl blank onto a piece of scrap wood where the scrap wood is screwed to a faceplate. Allows the bowl blank to avoid screw holes.

After turning the inside of the bowl, the bowl is easily removed by a sharp whack with a mallet.

Can be any paper, brown paper, writing paper, etc.

I glue both sides of the paper, normal yellow glue.
 

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Discussion Starter · #10 ·
Instead of gluing the cauls, why not just clamp them? Then there is no block to remove and clean up after, plus the cauls are reusable.

My head almost hit my desk.

Why don't I? Because I'm too obtuse to see a great solution that's right in front of me. I think that's the way to go! I avoid all the pitfalls of removing the cauls.

Thank you to all who chimed in. I'll post pics of the process and finished product in another thread!
 

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My head almost hit my desk.

Why don't I? Because I'm too obtuse to see a great solution that's right in front of me. I think that's the way to go! I avoid all the pitfalls of removing the cauls.

Thank you to all who chimed in. I'll post pics of the process and finished product in another thread!
I believe you've made a wise choice :thumbsup:
 

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I thought I would try the procedure David brought up. I holesawed a 4"x1-1/2" piece of oak, paper glued it to my home made faceplate. (Pine) My purpose was not to make a bowl but to test the procedure.

Machine Machine tool Wood


I got very aggressive with it just to see how well it would hold. Note the faceplate is sacrificial.

Wood


Wood


I used a parting tool on the bottom to shape it some and to see how far I could go with it. You can see a recess in the faceplate leaving about a 1/2" ring of paper left before it failed. :thumbsup::thumbsup:
Now to make a new faceplate and try it on a bigger bowl.


 
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