by Dremel ®
Tools & Accessories
1Wood (1 x 4) at least one foot long
1Clock mechanism (battery powered)
1Drill and small drill bit
1Small paint brush
Let's Get Started
To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.
The great thing about this project it that it doesn't take a lot of wood, and chances are you have enough scrap wood to make it. If not, you can buy a piece at your local hardware store for less than a cup of coffee. - Cut 1x4 to a length of 11" with Ultra-Saw - Make a 45º cut at 7" so you produce 2 pieces (7" and 4")
Using the Dremel Multi-Max and sanding attachment I started with the coarse grit, then applied wood filler, then sanded with medium, and finished out with fine.
Next, drill a hole for clock body. Depending on your clock hardware, you can place the hole where it fits best. I centered mine horizontally and measured 2.5" down from the top. I drilled out the hole based on the diameter of the clock stem. I also used my Dremel 8220 cordless rotary tool and a 196 high speed cutting bit to create a recessed area around the hole to allow for the clock stem nut to be tightened.
Now finish the wood. I wanted to create a strong contrast between front and back of the clock, so I opted to stain and clear-coat the front, and paint the back. - clean off dust and debris - follow stain instructions - follow poly coat instructions - be careful not to get stain on area to be painted (paint and stain do not mix well) Allow the stain time to dry, then: - mask-off stain area - paint back
Once all of your pieces have dried, its time to create the clock face. I started by printing out a template for number placement (every 30º along the perimeter of a circle). Then I pressed my pointed wood burning bit into the wood at each intersection to create number indicators on the face. Using a small paint brush I filled in each hole with orange paint.
Next, attach the 2 pieces of wood for your clock. Attaching the 2 pieces at an angle can be difficult, to help hold the parts together I added guide pins made from finish nails. - Drill 3 holes in the glue edge of the base - Glue in finish nails - Cut finish nails to approximately 1/4" sticks out - Align to top and mark pin placement - Drill corresponding holes in top - Apply wood glue, press together and allow to dry
Now you are ready to create the clock hand. The clock hand that came with the kit wasn't the style I wanted to use, so I printed a new one to match my color and style. - Take measurements from existing clock hand - Design hand in 3D software - Print on Dremel Idea builder
Finally, assemble your clock. Once you have all the pieces and the base affixed to the top, you can assemble the clock body and 3D printed hand. If you want you can add a piece of felt to the bottom for a finished look.