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Christmas star made of-pallet wood

My wife wanted to have a nice Christmas star for Christmas and that´s when the challenge hit me. In order to build the whole thing as accurately as possible, you have to pay attention to a few things that I would like to discuss at first.

Material Tools
3 pallet wood boards (depending on how big your star should be) Table saw
Wood glue Belt sander or belt-disc sander
  Abrasive paper
  Tension belts
  Soldering torch

Part 1: Theory

We start with some theory: (yes, unfortunately it has to be), if you are not really interested, you can skip it.

Acute angle

The star forms a closed circle, so let's do some math.

The circle has an angle of 360 degrees, furthermore our star should have 5 peaks therefore we calculate: 360 degrees / 5 = 72 degrees

Thus, each peak is at an angle of 72 degrees.

Since 3 peaks form a triangle, we must continue calculating:

In a triangle, the sum of all angles is 180 degrees.

As we 180 ° -72 ° -72 ° = 36 ° "rest" of the star peak.

To be able to saw the peak on mitre, the angle must be halved.

That means: 36 degrees / 2 = 18 degrees (peak).

But how I now saw the angle the best?

 

We take the example: circular saw

The saw blade is adjusted to 18 degrees and the board is guided perpendicular to the saw blade.

But be aware, it is not entirely harmless, because the workpiece can slip off the saw blade and into its slot.

To avoid this, the workpiece should be firmly clamped at the longitudinal stop.

The best way would be to build a guide carriage for the longitudinal stop, where the workpiece then is securely clamped on the saw blade and can be passed safely.

Or you build a suitable device for your guide carriage.

The other option would be to mark an angle on the workpiece and then saw it with the hand saw.

Thus, the "acute" angle is already sawed.

For this I have built a device.

With this device I can clamp the workpiece safely on the saw blade and guide it easily.

Dull angle

To obtain the second angle, we almost do the same.

The second angle at our star.

The second angle in our triangle is in principle a "dull triangle"!?!?!

How do I calculate this triangle?

That´s very easily.

We remember triangle ... angle ... 180 degrees

So we take the 180 ° -36 ° -36 ° = 108 ° "rest"

Now we have the total angle of 108 ° (degrees).

Because we sawed there as well on mitre, we have to halve this angle again.

That means: 108 degrees / 2 = 54 degrees

But how do we do this on the circular saw, my circular saw only can saw in a range between 0 to 45 degrees?

You need to know for this, that the saw blade is normally at 0 degrees to the saw table - which corresponds to an angle of 90 degrees. So perpendicular to the saw table.

So now we just calculate 90 ° - 54 ° = 36 ° degrees. Knowing that, we set the blade to 36 degrees and place the workpiece flat on our workbench. (Unfortunately I sawed at 38 degree)

Part 2: Sawing

After the whole theory now a little practice. ;)

We take 3 boards and saw with the circular saw 10 small boards out of them.

I have chosen a length of 20 cm, so my star will be 43 cm tall.

Then I put these boards in my device in order to be able to guide them safely on the saw blade on the longitudinal stop.

Afterwards I set an angle of 18 degrees with the circular saw.

And then used the device to saw these angles.

I did that with every board. And then the boards were finished with the 18-degree angle.

Then I took the angle stop and the longitudinal stop with spacer and set the saw blade to 38 degrees.

Now the boards were taken and put on the stop so that the 18 ° angle points away from the saw blade and the cut side points downwards.

The worst is over. ;)

Now all 10 boards are sanded with the belt and disc sander.

All sides are now sanded off the board, except the sawn side with the angle.

And the second part is completed.

Part 3: Assembly and finish

Now we want to put the sawn pieces together. For this I put the rest of a screen printing plate on my workbench to compensate unevenness.

After that, I put the boards together in pairs and then painted the tips on one side with wood glue.

Subsequently, two boards are always glued to a tip, clamped together with staples and then let them dry.

After drying, remove the clips and fold the individual tips into a star to check if the edges fit together.

If everything fits, all tips are turned clockwise and the edges, which then point upwards, coated with glue.

Then we turn the tips counterclockwise again and join them together. Then the star is lashed tight with a tension belt and weighted from above, but the latter is not absolutely necessary.

If you do not have any straps, you can also use expander ropes instead. Now it's time to let it dry again.

After everything dried, the straps and the excess glue are removed and everything is sanded again with the rotating sander.

Then our star is now ready for further processing.

For this I make use of a soldering torch and torched the star to give it a rustic look.

And that the Christmas spirit comes to its best advantage, I wrapped a small chain of lights around the star.

Part 4: Other

I needed almost 2 hours for the whole project. without the waiting time while drying.

I wish you all a Merry Christmas and a nice time with your loved ones.

 

Thanks for reading and have fun building the star.

Klaus Schäfer

AuthorKlaus Schäfer
Reading time10 minutes

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