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April 2023 (Part 01)

Steve's Present For Andy - Carving of the Penn State Nittany Lion Statue

Steve made a set of corn hole boards for Andy's high school graduation.  Well the Nittany Lion sticker was peeling up badly and we needed a set for the beach ... so, we can rebuild it, we have the technology ...  With a fresh sheet of plywood and a little lessons learned, Steve made four more boards and rebuilt part of Andy's.  His original sides were 2x4s, which were really heavy combined with the 3/4 plywood used.  They four new boards have sanded 1/2 plywood and 1x4s for the sides.  So much lighter.  Didn't provide a new top for Andy's, but did redo the sides.  All of the boards then got hand painted lettering and logos.  Can't believe how long this project took.  The U of I and U of M boards will stay home, while the US Air Force boards are headed to the beach.

With the corn hole boards finally done and the woodshop cleaned up, Steve had an ambitious idea, to make a carving of the Penn State Nittany Lion Statue for Andy's graduation.  Now it's time for a crash program on this project as graduation is in about a month.  Nothing like pressure for the first real attempt at carving something.

He had taken pictures of the status from all sides on a prior trip to Penn State, and had paced out the overall dimensions.  Luckily, there is someone he works with who has a 3D printer.  Steve found and sent him a file and he was able to print a small version.  Steve was thinking he might be able to use this to get better dimensions (especially internal and relative sizes).  In discussing this, they realized that the file used for the print could be used instead.  He was able to rotate the image and print from several views including the sides and top at the length he needed.  Then using this and some carbon paper, got the overall outline transferred to the wood, which then allowed him to take some of the big areas off with the bandsaw.

Not sure where to start.  Since the tail overhangs the pedestal (as does the front left paw), that looked like as good a place as any.

I used the carbon paper to trace the outline on the top.

I think the only thing I'm making quickly is wood shavings.

OK, strong progress this weekend.  Here is the carving by Saturday.

Here is the status as of Sunday.  Worked almost all day.  My shoulders are killing me.  The shape is all there.  Now to cut in the paws and face a bit better and I should be ready to start sanding.  Then to work on the base and whatever lettering to put on the bottom.

Carving essentially done, including the lettering in the bottom.  Sanded a bit of its right side to see how it would look.  Less than a week to go until Andy's graduation party.  Time to get sanding.

A bit more progress.  The lion is mostly sanded.  This is how Andy first saw it as I wasn't able to completely finish it before graduation.  Still need to finish sanding and then repair several of the letters (as the inside of the e's and a g all popped off when carving), then stain and seal the project.  Then to start with Lexi's ....