Whirligig Stand

Plans for Whirligig Stand

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Whirligig Design & Development
Whirligig Stand
List of Materials


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Read the directions through before starting.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Special Tools

General Wheel & Circle Cutter, Part # 06
Small Drill Press

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Top Cap

1. With the General circle cutter, cut the Top Cap from 3/4" thick African mahogany or equivalent wood.
2. It is optional whether you rout the top or not.
3. Do not drill the 11/16” diameter hole at this time.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Top Base - step 1

1. With the General circle cutter, cut the Top Base from 3/4” African mahogany or equivalent wood. At the same time cut the wood for the Base.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Top Base - step 2

1. When laying out the leg holes, try to avoid having the wood grain lining up with the center and any of the holes. On a drill press, drill the three 3/4” diameter holes for the legs in the Top Base and Base with a paddle bit.
2. On a drill press, drill the six 5/16” diameter holes for the threaded inserts in the Top Base and Base. (Check the pilot hole requirements for your particular inserts. Some require a 3/8” diameter hole.)

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Assembling Whirligig Stand Top

1. Using exterior rated glue, glue the Top Cap to the Top Base. Orient the wood grain of the two pieces at right angles or as near to a right angle as possible. This will help prevent the wood from splitting on long exposure to outside weather conditions.
2. After the glue has dried, drill the 11/16” diameter hole in the top assembly and the Base.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Base

1. The Base is identical to the Top Base except the 11/16" diameter hole does not go all the way through.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Dowel Insert

1. 

1. If a 5/8" diameter dowel of mahogany or other suitable wood is not available, fashion one to the dimensions given in the plan.
2. Put the 4 1/2" brass rod into the hole in the Dowel Insert.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Whirligig Support

1. Cut from a length of 1/2" steel EMT.
2. After drilling the 5/32" diameter hole, file the burrs from inside the tube and slide in the Dowel Insert and brass rod.
3. Fasten the Dowel Insert and brass rod in place with the #8 x 1/2" sheet metal screw.
4. Drill a 1/4" diameter hole in the 5/8" nylon cap. Put it over the 1/4" diameter rod, and push it into the Whirligig Support.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Leg (3 needed)

1. Decide which size stand you will make. The two leg lengths given in the plans give a nicely proportioned stand. The taller stand looks better with larger, more complicated whirligigs. Do not make the stand any shorter than shown in the plans. The stand, as dimensioned, will put the whirligig at or above eye level. This gives the whole assembly a "presence."
2. Cut the legs to length from the 1/2" steel EMT. Mark where the bend is to be made, which is the same for either length leg, 13 1/2".
3. Insert the 1/2" steel EMT into a length of 3/4" steel EMT up to the mark. You need to do this to get a sharp bend in the 1/2" steel EMT. Secure the 1/2" steel EMT firmly in place. Bend the 1/2" steel EMT to the desired offset.

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Chuck Dunbar's
Whirligig Design & Development
Whirligig Stand
Assembly

• Before assembling the Whirligig Stand, put the brass inserts into their holes in the Top Base and Base. Screw in the thumbscrews.
• Put the eyebolt through the 1/4" diameter hole in the center of the Base from the bottom. Put on a washer and 2 nuts. Tighten the nuts against one another. The eyebolt gives a point from which a weight can be hung.
• Insert the Whirligig Support through the center holes in the Cap and Base.
• Insert the legs one at a time into the 3/4" diameter holes in the Cap and Base. Tighten the thumbscrews. Once all the legs are in place, make any final adjustments.
• Put a washer over the 1/4" rod. Add a few drops of oil to the rod. Put the whirligig over the rod.

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