we just finished a project for a local interior design firm that involved making 12 new feet for 2 big couches whose feet were not really in proportion to the rest of them, or to the room where they went ... the new feet are 7" in diameter, 7" high. we glued up some blocks from8/4 and made a sample and a template for the duplicator and had at it. before will could start turning them, i cut them to length and round for him. will had recently tuned up the bandsaw, adjusted the guides, etc. etc., but i didn't realize what a good job he had done until i cut the blanks ... square ... straight ... cut after cut, through 7 " of maple ... click the photos to enlarge them ..
in response to the comment below, i am posting a link to the bandsaw blades we use. THE most important part of the tune up is a new blade from doall. we've tried many brands i won't name, but these are, in our opinion, THE best. i have to go to the shop to find the exact info ... next is to adjust your guides close to the teeth and square your fence to the table and the blade ... fussy stuff but worth the effort. see the last photos below.
this is how they lined up across the top of a stack 3 high ... barely a 32nd difference across the tops.
the chips flew during the rough out stage ...
and made quite a pile ...
first coat of stain ... after distressing we used a second coat of english brown mahogany lockwood water stain. then a coat of oil/poly, then gel stain on the lathe spinning on low speed. the final coat of satin poly was brushed on with the feet on the lathe, and then they were transferred to the finish room to dry where you see them below.
all in, all done ... they will be installed to the couch frames with 2 - 8" timberlock screws per foot
in the photo above, you can see a stack of 9 - .1" veneers cut sequentially and sanded after from one piece of 8/4 walnut. and 4 - 10.5" wide curly hard maple slices also from one board.