Best way to cut long thin spindles for Windsor chair?

I am building two windsors now. The method I used for the long spindles is to
begin with straight grain ash. I cut the long spindles 3/4 inch square on a
table saw. I found a three inch piece of pipe at the hardware store that is a
tight fit and slip that onto the middle of the long spindle. My spindles are
34 inches. I then use a three wheel steady rest to control the smooth spinning
pipe section. I turn round on both sides of the pipe section to each end. I
then remove the pipe section and simpley let the steady rest run on the
sections I just turned while I finish the few inches that were inside the pipe
section. A piece of pipe used this way has a name and it is not new, but I
can't recall what it is called. The technique removes all of the vibration. I
used some old open end wrenches, 1/2" and 5/8" to determine the proper size. I
would cut down with a parting tool until the wrench slipped over the turning
and that would tell me I had uniform size. Actually I cut several places along
the full length of the spindle, then use a shallow gouge and "connect" the
areas that are properly turned. I did not find a need to use my hand to steady
the piece once I found this method. I will say that straight grain wood is a
must. If you do not have that you will get vibration and whip no matter what
else you do. GCS

Lathe and steady has been the way for many years. Help yourself slightly by
having a ball-bearing cup center at he tail end. Don't tighten it into the
piece, just make contact, to keep from whipping.

I mount long stuff on the lathe and take the corners off with a block plane
with my spindle locked. You can get pretty close to round before you even
turn the lathe on. After that, I prefer the straight portion of a big
roughing gouge for planing cuts.

If you decide to build a bodger's bench and have a go with hand tools, check
out the LV low-angle shave.

"David Anderson" <[email protected]> wrote in message
news:[email protected]...
> My examination of 200 year old antique Windsor chair spindles seems to
> reveal that they were handmade with a spokeshave. Some of the fancy
spindles
> even had a bulb about 1/4 the way up. That works for me, too, but it is
sure
> labor-intensive. Anyone successfully made these with machine tools?
> Typical spindle might be 5/8 or 11/16 inch on the big end, tapering
> uniformly to about 3/8 inch on the top end, and from 30 to 33 inches long.
> I've tried three different machine methods, but none have satisfied me so
> far. Start with 3/4 inch square white oak or hickory straight grained
stock.
>

Fred Lambert rounder and trapping plane on a slow-running lathe.

http://www.crafts32.fsnet.co.uk/products_rotary_planes.htm

Don't know if they've made it to the US yet.

Cheers

Frank


"David Anderson" <[email protected]> wrote in message
news:[email protected]...
> My examination of 200 year old antique Windsor chair spindles seems to
> reveal that they were handmade with a spokeshave. Some of the fancy
spindles
> even had a bulb about 1/4 the way up. That works for me, too, but it is
sure
> labor-intensive. Anyone successfully made these with machine tools?
> Typical spindle might be 5/8 or 11/16 inch on the big end, tapering
> uniformly to about 3/8 inch on the top end, and from 30 to 33 inches long.
> I've tried three different machine methods, but none have satisfied me so
> far. Start with 3/4 inch square white oak or hickory straight grained
stock.
>
> 1) Turn in 16x54 inch wood lathe at 2000 rpm using a leather glove on one
> hand to provide a continuous steady rest while cutting with a gouge with
the
> other hand. Finish with spokeshave.
>
> 2) With either over-arm or portable router and quarter-round bit, make
four
> passes to produce a round section; then change to a smaller bit and repeat
> part way; finish by hand spokeshave.
>
> 3) I've made several hollow mills with three-lips, rotating at high speed
in
> the wood lathe headstock to make the first cut from the square stock.
Then
> a second pass at a smaller diameter, etc. Mills are made from 1 inch OD
> drill rod, hardened to Rc60-62, ground to a sharp edge. Still a lot of
work
> because it will still only cut a single constant diameter..
>
> 4) Go back 200 years, and make with a spokeshave. That works, but it is
> expensive.
>
> Any great ideas? Thanks, Dave
>
>

Think Swiss Screw Machine.

On Wed, 14 Jul 2004 02:54:13 GMT, "David Anderson"
<[email protected]> wrote:

>My examination of 200 year old antique Windsor chair spindles seems to
>reveal that they were handmade with a spokeshave. Some of the fancy spindles
>even had a bulb about 1/4 the way up. That works for me, too, but it is sure
>labor-intensive. Anyone successfully made these with machine tools?
>Typical spindle might be 5/8 or 11/16 inch on the big end, tapering
>uniformly to about 3/8 inch on the top end, and from 30 to 33 inches long.
>I've tried three different machine methods, but none have satisfied me so
>far. Start with 3/4 inch square white oak or hickory straight grained stock.
>
>1) Turn in 16x54 inch wood lathe at 2000 rpm using a leather glove on one
>hand to provide a continuous steady rest while cutting with a gouge with the
>other hand. Finish with spokeshave.
>
>2) With either over-arm or portable router and quarter-round bit, make four
>passes to produce a round section; then change to a smaller bit and repeat
>part way; finish by hand spokeshave.
>
>3) I've made several hollow mills with three-lips, rotating at high speed in
>the wood lathe headstock to make the first cut from the square stock. Then
>a second pass at a smaller diameter, etc. Mills are made from 1 inch OD
>drill rod, hardened to Rc60-62, ground to a sharp edge. Still a lot of work
>because it will still only cut a single constant diameter..
>
>4) Go back 200 years, and make with a spokeshave. That works, but it is
>expensive.
>
>Any great ideas? Thanks, Dave
>