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I needed hands to replace ones that fell apart when I restored a very old cuckoo clock. This is the process that worked for me.
Tools I used:
Step 1:
I purchased guitar saddle blanks that measure 3” x 3/4” x 3mm. It was not necessary to cut the length or width, but I had to grind the thickness. The hands that I used for the pattern were about 1.55mm thick. After using the grinder for the bulk of it I sanded to smooth out the ridges that the grinding wheel made until the blank measured about 1.8mm thick.Step 2:
Next, I used Elmer’s school glue to attach the bone blank to a tongue depressor. This gives rigidity, as well as, more surface to hold onto while working. I made a copy of the original bone hands and transferred the outline to the bone blank.
Step 3:
Then I used a Dremel with a diamond cutting disc to make release cuts along the edge of the bone. This will allow me to back the saw in and out easier.
Step 4:
The next step is to saw along the outline using a jeweler’s saw. This takes some getting used to and practice. I broke many blades. Now I know why they sell these blades in 144 packs! The blade that I found to work the best for me was size #1/0. I tried to get as close to the line as possible without cutting off the line. I am actually holding the saw upside down in this picture. It works better if it’s held the correct way.
Step 5:
I did some of the initial filing around the pattern with it in the vise. If I had areas that needed a lot of material gone, I very carefully used the Dremel to quickly file. Also, the area that needed cut out was drilled so I could feed the blade of the saw through the hole for cutting. I actually did most of the detail filing in my hands, not using the vise but being mindful of where and how much pressure I was putting on the delicate parts.
Step 6:
After I was satisfied with the filing around the outline, I sanded on a flat surface until the thickness of the bone was about 1.55mm. Notice that I have not yet cut out the point of the hand. I left this until the last for fear of breaking it off and also I needed the end of the tongue depressor to use as a handle while sanding.
Step 7:
When I was finished filing the thickness, I reattached the pattern and redrew the point of the hand, then finished cutting and filing.
Step 8:
To remove the wood from the hand, I soaked it in warm water until the glue released. I VERY carefully inserted the blade of an exacto knife between the wood and bone at the round end to help it along. If I had been patient it probably would have released on its own which would have been a lot safer.
I could see now places that needed additional filing and shaping. So, finishing touches were done very delicately.Step 9:
I put the jeweler’s saw blade through the hole I drilled at the end of the minute hand and cut out the square. Then on my drill press I drilled the round hole for the hour hand. I had to do some additional filing to fit the hands onto the clock. Just be sure to take it slowly only removing a little and then trying the fit.
Step 10:
To stain the hands I put them in strong hot coffee for about 30 seconds and then wiped them dry.
Here is the finished project!
“Bone” appetit!
Andrea
Andrea, excellent thread, you made me smile, then…I saw my teeth 😯 …I love coffee
I would have never thought of using my favorite beverage to darken the hands. I guess the saying is true, sometimes the answer is right under your nose .
Guitar saddle blanks are a perfect supply for bone blanks, good idea!
Those hands look great, thank you for posting this, I will definitely refer to it when I need to make some bones hands, or for that matter any cuckoo hands as I am sure most of the techniques would work for plastic and wood too.
Keep on keepin on.
WilliamVery nicely done!
I am so pleased I now have someone to contact when I need new cuckoo hands making
Great tutorial, thank you for taking the time to post it up Andrea.
Paul.Thank you, Paul. Don’t know how soon I’ll be dong that again! Don’t get me wrong. I enjoyed it but it is time consuming, especially because I was learning as I went along. Someday after all the clocks that are waiting for me are finished, I’d like to try something more detailed.
(that might be a while).Andrea
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