Fun with Wooden Balls

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Have you ever found the need to make your own wooden balls for a project? To be frank, we haven’t either! But seriously — how would you do it? Well, lucky for us, Hackaday Alum [Jeremy Cook] has experimented with a few different methods.

He was originally inspired by this video from [Philip Stephens] who makes them completely by hand using a hand-made hole saw. Not wanting to spend hours making a ball, he thought about ways to automate it — well, kind of.

His first attempt was to use a mill and a rudimentary rotary index table consisting of a wood clamp — Hold a wooden dowel in place, hole saw halfway through, rotate in the clamp, repeat times infinity. Eventually you’ll be left with a wooden ball whose sharp edges you can just break off. Not very satisfied with this method, he discovered a Reddit thread on making wooden balls with a rather ingenious method… Stick around after the break to see how.

First up is the rather slow hole saw method:

But here’s the cooler way to do it. Orbital sander, plus a tube — let the wood bounce around and quickly erode into a perfect sphere!

Comments

  1. squeeks says:

    I always find wood shops interesting, the people who seem to occupy this type of habitat are usually fascinating and will make a large number of their own tools or heavily retrofit existing ones.

    The lathe should have been explored a little more, it is almost designed perfectly for the task…

    • Peter Sanders says:

      Blacksmith shops too… lots of shop made tools there too..

    • Tony says:

      Ball bearing are made by placing bits cut off wire between two abrasive plates.

      So for this keep the set-up as is, but put another disc into the mill chuck, and turn it on. Add a ring the size of the discs to keep the ball contained.

      Gradually lower the mill head until the desired size is reached.

      Like the ball bearing, keep switching the abrasive to finer graded until polished.

      Of course a mill won’t spin anywhere near as fast as a router so using two routers would be a better idea. (A tad noisy though…)

  2. trollmaster3000 says:

    Balls XD

  3. Hirudinea says:

    “Have you ever found the need to make your own wooden balls for a project? To be frank, we haven’t either!”, you’ve obvious never heard of Geppetto. The orbital sander method is interesting, if not the most accurate method in the world, if they could be made rounder they’ed be good for ball bearings in large projects.

  4. GPPK says:

    I would buy some wood filament and 3d print them…

  5. tekkieneet says:

    First step for DIY Minority Report?

  6. Chris Tree says:

    You can make a great ball cutter for a lathe. The cutting tool rotates around an ark while the material spins. Super accurate too

  7. josh says:

    Hobby shops like Ben Franklins and Hobby Lobby sell wooden spheres. It is a neat idea, but seems like a waste of time to me.

  8. Mike W says:

    Wow, they are going about it all wrong. I make wooden balls for children’s toys.
    I can make eight at a time on my Shop Smith lathe.
    Just insert a length of square stock, and cut the balls in a line.
    Then using a small saw, cut them apart and sand the ends.
    Each ball is identical in size, and only need minor sanding to make them smooth and perfectly round. Takes less than an hour to make eight.
    I even taught an eight year old how to do it with adult supervision.

  9. Freddy says:

    1. That wasn’t a sphere. It looked like a potato.

    2. It’s impossible to make two similar sized potatoes with this method.

    How about using a lathe?

  10. Chris Parker (@ironring1) says:

    Cool idea, but it will ruin that mill’s accuracy. Whenever an absorptive material is finely cut on a metal-working tool, dust makes its way on to the ways (linear bearing surfaces), where it picks up oil and can distort the movement.

  11. 1.21Gigawatts says:

    Nobody does balls as good as Pete Schweddy.

  12. uri says:

    Work an hour to make a 30 cent wooden ball which are sold at Michaels.
    Now stone is a different item. I used to see them make stone balls at rock shows where they used 3 pieces of tubing attached to small motors configured in a triangle.

  13. Erich. says:

    I recall a technique I saw in scientific american in which a rough approximation of a ball is spun in a lathe, and the cutting tool used to smooth off the lumps is a metal pipe. The rim of the working end of the metal pipe is chamfered to a cutting edge, not unlike a hole cutter used for cork or rubber. Net result, a circular cutting edge is worked over the surface of the rough shaped ball, resulting in a smoothed, fairly spehrical surface.

  14. Jeremy Cook says:

    Thanks for publishing this James!

    A lathe (or purchase) would probably be better, but the experimentation is most of the fun.

  15. just run it through a band saw on a tilted table twice and then finish on a lathe.

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