Turning a Cupcake Box with Ron Pollmann

To turn a cupcake box, starting with a blank: 3″ X 3″ X 4″ (76mm x 76mm x 102mm) – maple or other close-grained hardwood

Ron Pollmann’s original video demonstration follows the steps list below.

OperationComments

1. Cupcake base

   • Mount blank between centers and rough blank round, then make tenon to fit chuck jawsRoughing gouge/parting tool
   • Reverse mount blank in chuck and mark bottom of cupcake base at 2″ (50 mm) from tailstock endPencil
   • Cut 2.6″ (65mm) top diameter of cupcake base and 2″ (50mm) bottom diameter of cupcake base1/8″ Parting tool / caliper
   • Cut 1/8″ into blank to left of cupcake bottom to allow room for router tool movement1/8″ Parting tool
   • Taper cupcake base in straight line from top diameter to bottom diameter, check with straightedgeRoughing gouge / skew/straight edge
   • Flatten top edge of cupcake base about 1/2″ (13 mm) in from edge towards centerSkew

2. Turn cupcake base with 24 flute cuts

   • Replace tool rest with router platformRouter platform
   • Align tip of router bit with tailstock live centerRouter with 90 degree bit
   • Align front edge of router platform with taper of cupcake base, with router bit extending – 1/8″ (3mm) into base —
   • Turn off / unplug lathe and wear hearing protectionImportant safety tip
   • Bring up tailstock and lock lathe indexer into first indent —
   • Move router slowly down length of cupcake base, cutting first fluteSwitch on router away from blank
   • Move indexer to second indent and make second router cut —
   • Readjust router platform depth into blank until a perfect flute is formed by these first two cuts —
   • Move indexer and make all remaining flute cuts —
   • Sand flutes, remove dust with brush and clean flutes with denatured alcohol – helps with color saturation240 grit sandpaper/brush/DNA
   • Color flutes with Tombow markersTombow markers

3. Hollow cupcake base

   • Lid OD: mark top of cupcake base ~1/8″ (3mm) from bottom of flutes, this diameter needs to be ~ 52mmPencil/ruler or caliper
   • Mount Jacobs chuck in tailstock with 1.25″ (32mm) Forstner bitJacobs chuck/1.25″ Forstner bit
   • Drill hole 1.6″ (40 mm) deep in cupcake base —
   • Lid OD: Cut 1/8″ (3 mm) deep lip for cupcake lidParting tool
   • Hollow cupcake base to lid ID leaving ~ 1/8″ (3mm) for lid recess, use straw/compressed air to clear chipsScraper / carbide hollowing tool / straw
   • Sand inside of cupcake base240/320 grit sandpaper – 500 rpm

4. Part off cupcake base

   • Double check depth of cupcake base before next step to ensure you don’t make a funnelDepth gauge
   • Cut off cupcake base at about 1 3/4″ (45 mm), slightly undercuting bottomParting tool

OperationTool / Comments

1. Cupcake lid

   • Flatten face of blank that remains in chuckSkew or parting tool
   • Measure cupcake base lip OD, set caliper to slightly larger than this diameter Caliper
   • Cut tenon on blank to lip OD diameter, testing fit of cupcake base until base fits tightly into lid tenonParting tool / caliper
   • Slide cupcake base onto tenon and mark outside diameter of flutes on lid blank Pencil
   • Cut from outside diameter line to tenon, depth to match lid recess in cupcake base1/8″ parting tool
   • Test fit cupcake base to ensure flutes fit inside lid —
   • Cut back tenon to ensure lid fits inside base (lid slightly overhangs flutes), cut small relief on lid tenonParting tool
   • Begin shaping top of lid, leaving 1/16″ (1.5mm) to 1/8″ (3mm)outside of flutes for lid overhang3/8″ spindle gouge
   • Reverse chuck top and finish dome of lid3/8″ spindle gouge/skew
   • Sand lid top, remove dust and clean with denatured alcohol240 grit sandpaper/DNA – 500 rpm
   • Use markers to color four concentric rings on top of lidTombow markers
   • Texture four concentric rings in top of lid500 rpm
     • center ring with knurling tool at centerline of lidknurling tool
     • second ring with knurling tool above centerline of lidknurling tool
     • third ring with knurling tool below centerline of lidknurling tool
     • final ring with knurling tool at centerline of lidknurling tool
   • Re-color concentric rings to saturate texturing, if desiredTombow markers
   • Remove lid and color bottom or leave naturalTombow markers

2. Finish cupcake base bottom

   • Reverse mount cupcake base and clean up cupcake bottomParting tool/skew
   • Sand bottom of cupcake bottom, remove dust with brush and clean with denatured alcohol240/320 grit sandpaper, brush, DNA
   • Color bottom of cupcake baseTombow markers
   • Inside of cupcake base: remove dust, clean with denatured alcohol and color or leave naturalTombow markers

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