DIY Network

Assembling the Clock The final step is to put the wall clock together. From "Freeform Furniture" episode DFFF-201

Host Amy Devers assembles the clock. She uses an awl to mark where the hole will go to attach the hands, a compass to plot the circumference for where the hands will spin around and a ruler to mark where the numbers will go.

The holes are drilled to insert the numbers and the center hole. As a final step, she puts in the high torque quartz movement, attaches the hands and inserts the battery.

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	Amy installs the quartz movement and finishes the unique wall clock.
	The finished clock

Materials:

laminate
dye-cut tin hands
upholstery tacks
medium-density fiberboard
tempered hardboard
flexible curve
compass
minute hand of clock
pencil
paper
straight edge ruler
square ruler
spray adhesive
respirator
safety goggles
yellow wood glue
double stick adhesive tape
water-based contact cement
paint-trim roller
clear packing tape
brown craft paper
paint
pliers
screw
nut
hex nut
awl
blue tape
forstner bit
counter sink bit
eraser
high torque quartz movement
AA battery

Tools:

drill
jigsaw
band saw
spindle sander
laminate trimmer
hand clamps
wood file
pneumatic nailer
flush trimming bit
"J" roller
mallet

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

Assembling the Clock

1. Figure out where to drill the hole to attach the hands. Use a straight edge ruler to find the center point, measuring in from the four widest curves.

2. Mark the center point with an awl. An awl is just a tool with a handle and a small point for punching small holes (figure A).

3. Use a compass to plot the circumference for where you want the hands to spin around.

4. Use the ruler again to mark where the numbers will go.

5. Drill in the holes you need so you can insert the numbers.

   Tip: Blue tape on the drill helps insure that you don't drill too deep (figure B).

6. Switch out drills and use a forstner bit for the center hole (figure C). (The forstner bit is good to use when you need to make a wide hole with a flat bottom.)

7. Switch back to a regular drill bit and make a smaller hole inside the center hole for the post of the clock movement. Be careful to hold the drill straight and perpendicular to the wood.

8. Erase the lines off the clock face.

9. Use a mallet to tap in the black upholstery tacks that you use as numbers.

10. The high torque quartz movement is the heartbeat of the clock (figure D). It is what makes the hands move around so you can tell what time it is.

11. Slide a post through the hole and then tighten it down with a hex nut.

12. Lock on the hands and tighten those on with a tiny little nut. It only takes one AA battery.

13. Flip the clock over, insert the mechanism, flip it back over and push the post of the mechanism back into place.

14. Place the next nut on the post and tighten it with a pair of pliers.

15. Place the hands on the post and secure them with a nut (figure E).

16. Put the battery in place and set the time.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Adhesives, Abrasives and Safety Equipment
3M
The 3M Company
Website: www.3m.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Delta Power Tools
Website: www.deltaportercable.com

WMH Tool Group
Website: www.whmtoolgroup.com

Lie-Nielsen Tookworks, Inc.
Website: www.lie-nielson.com

Wilsonart Laminate
Website: www.wilsonart.com

MacBeath Hardwood
Website: www.macbeath.com