Alphorn Experiment #5: Joining and Completing the Bell

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This is part 5 in a 5 part series: Alphorn Experiment

  1. Concept and Design
...
  1. Joining the Straight Sections
  2. Joining and Completing the Bell

The last step before applying a finish to everything was completing the bell.  As I mentioned at the end of Chapter 2 about making the bell on my CNC, I had removed the recess for the external sleeve from the components  when machining the parts for the bell.  This turned out to be quite a pain to deal with.  My original plan was to try to cut and shape the recess by hand but that was going to take forever and challenges during the glue up made that even worse.  Instead I decided to use my router table with a profile bit to remove most of the wood.  This was risky but I figured  that this is an experiment after all and if I destroyed the bell, I would make some design tweaks and remake the bell to eliminate this step. 

This required that I insert a guide into the end for the bearing to follow.  Because after glue up challenges the end turned out to not be round, this meant that I had to make a a template that basically converted the oval shape on the inside to a round one on the outside that matched the shape and size of the recess of the joining straight section.  Here is the insert that I made and the setup on my router table.  The insert fit tightly into the end of the bell and I clamped a scrap of  MDF  to the table  so that the guide could rest against it and the bearing at the same time for stability. 


This was a scary process as I had to balance the tall curved bell on top of the router table while slowly turning it.  I did it in two passes and left some extra material to sneak up on a final fit.   I did not get any pictures of the process but here it is after the first pass.