Metal Spinning Using Wood Turned Molds with Jim Kelley

Introduction

This tutorial will guide you through the process of metal spinning using wood-turned molds, inspired by Jim Kelley's presentation at a woodworkers' gathering. Metal spinning is a fascinating technique that allows you to create shapes and forms from metal, and using wood molds can enhance the quality and efficiency of your work. Whether you're a seasoned woodworker or a beginner, this guide will provide you with actionable steps to get started.

Step 1: Prepare Your Wood Mold

Creating a wood mold is critical for successful metal spinning. Here’s how to do it:

1. Select the Wood:

   • Choose a dense type of wood, such as hardwood, for durability.

2. Shape the Mold:

   • Use a lathe to turn the wood into the desired shape.
   • Ensure the surface is smooth to avoid imperfections in the metal.

3. Finish the Mold:

   • Sand the mold thoroughly to achieve a fine finish.
   • Apply a release agent like Briwax Natural Creamed Beeswax to ease the metal's removal after spinning.

Step 2: Prepare the Metal Sheet

Before you start spinning, prepare your metal sheet:

1. Choose the Right Metal:

   • Common metals for spinning include aluminum, brass, and copper due to their malleability.

2. Cut the Metal:

   • Cut the metal sheet to a size slightly larger than the mold to allow for forming.

3. Heat the Metal (Optional):

   • For some metals, heating can make them more pliable, facilitating easier spinning.

Step 3: Set Up the Spinning Machine

Getting your machine ready is crucial for the spinning process:

1. Install the Mold:

   • Securely attach the wood mold to the spinning lathe.

2. Position the Metal:

   • Place the metal sheet over the mold, ensuring it is centered.

3. Adjust Settings:

   • Set the speed of the lathe according to the metal type and thickness.

Step 4: Perform the Spinning Process

Now it’s time to spin the metal:

1. Start the Lathe:

   • Gradually increase the speed as you begin.

2. Shape the Metal:

   • Use a wooden or rubber tool to push the metal against the mold gently.
   • Work from the edges inward to form a smooth shape.

3. Continue Spinning:

   • Maintain consistent pressure and speed until the metal conforms to the mold.

Step 5: Finishing Touches

After spinning, you’ll need to complete the process:

1. Remove the Metal:

   • Once cooled, carefully remove the formed metal from the mold.

2. Trim Excess Material:

   • Use shears or a cutting tool to trim any excess metal for a clean finish.

3. Polish the Finished Piece:

   • Sand and polish the metal to achieve the desired sheen and smoothness.

Conclusion

Metal spinning using wood-turned molds can be an exciting and rewarding woodworking project. By following these steps—preparing your mold, selecting and prepping your metal, setting up your machine, and completing the spinning process—you’ll be able to create unique metal forms. For your next steps, consider experimenting with different shapes and metals, or joining a local woodworking group to share ideas and techniques. Happy spinning!