sundial.pdf

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Although I still haven't thrown away my watch, and hardly ever run to the garden to see
what time it is, it's still fun to have this sundial in my yard. I painted mine a bright red, but you
can choose another color or simply stain it.
The column is easy to build out of exterior plywood and 2 x 8 pressure-treated pine. (I used
pressure-treated pine). Be sure to only use exterior-grade materials, including your lumber,
fasteners, adhesive, and finish. You can find the brass fixture, the sundial itself, at most garden
shops and building-supply stores. The finished sundial is approximately 16 inches in diameter
and about 36 inches tall.
Materials
Lumber:
• 8 x 14-inch piece of 3/4-inch-thick exterior plywood
• 18 linear feet of pressure-treated 2 x 8 lumber
• 5 linear feet of 3-1/2-inch-wide decorative trim
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undial
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Hardware
• Approx. 20 #6 2-1/2”-long galvanized flathead wood screws
• Approx. 20 8d 2-1/2”-long galvanized finishing nails
• Approx. 100 6d galvanized finishing nails
• Approx. 20 8d galvanized finishing nails
• Brass sundial, approximately 10-1/2 inches in diameter.
• Approx. 16 brass upholstery tacks
Cutting List:
Code Description Qty.
Material
Dimensions
A Top
1 ¾” exterior-grade
plywood
See Fig. 1 (Approx. 13” x
15”)
B Inner Support
1 ¾” exterior-grade
plywood
See Fig. 2 (Approx. 10” x
11”)
C Column Side
6 2 x 8 treated lumber
35” long
D Trim
6 3-1/2” decorative trim
Cut to fit (Approx. 54”
total)
Getting the Parts Ready
1. A pattern for the top (A) is given in Figure 1 . It is a hexagon with all sides measuring
exactly 7-1/2 inches and all angles measuring 60-degrees. Enlarge the pattern and cut one
top (A) from ¾”-thick plywood.
(Enlarge by 800%
to get actual size.)
Figure 1
2. Figure 2 shows the pattern for the inner support (B). It is a smaller hexagon, and all of its
sides measure 5-1/2 inches. Enlarge the pattern and cut one inner supports (B) from ¾”-
thick exterior plywood.
2
108270626.042.png
(Enlarge by 800%
to get actual size.)
Figure 2
3. Cut six column sides (C) from 2 x 8 pressure-treated wood, each measuring 35 inches long.
4. Set your saw blade to cut 30 degrees off vertical, and bevel both 35”-long sides of all six
column sides at a 60-degree angle, as shown in Figure 3 . Note that the bevels are mirror
images of each other.
Figure 3
Assembling the Column:
1. This assembly is simple to do, but there are lots of parts to be handled at one time. You
may wish to enlist the assistance of a willing helper.
2. The first step is to attach one end of all six of the column sides (C) to the top (A). Stand the
column sides so they form a circle. As shown in Figure 4, the narrower face of each
column side (C) is oriented toward the inside of the circle
3. Place the top (A) over the upper ends of the column sides (C). Make certain that the edges
of the top (A) are flush with the outer surface of the column sides (C). Glue and screw
through the top (A) into the top edge of the column sides (C). Use two 2-1/2-inch-long
screws into each of the column sides (C). Countersink the screws.
4. Turn the column upside-down, and fit the inner support (B) inside the circle formed by the
column sides (C). Position the inner support (B) about 4 inches from the ends of the column
sides.
5. Glue and nail the inner support (B) in place. Use 8-penny finishing nails and drive two
nails through each of the column sides (C) into the edge of the inner support (B).
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Countersink the nails.
6. Use 6-penny nails to reinforce each of the joints between the column sides. Nail through
the beveled edge of one column side (C) into the beveled edge of the adjoining column side
(C) spacing the nails about 6 inches apart down the length of the joint. Countersink the
nails.
Adding the Trim
1. Carefully measure and cut six pieces of 3-1/2”-wide decorative trim (D) to fit around the
top of the column. It is easier if you cut one piece at a time and give yourself a little extra
length for cutting the miters. Standing the trim pieces (D) on edge, miter both ends of each
piece. Set your saw to cut at 30 degrees, producing an angle of 60 degrees on the wood.
These miters match the bevels in the column sides.
2. Glue and nail the decorative trim pieces (D) on each side of the columns, positioning the
pieces so that the thicker edges are flush with the top (A). Use two 2-penny finishing nails
to secure each of the trim pieces (D).
Finishing
1. Fill any exposed nail and screw holes with wood
filler.
2. Sand the completed column.
3. Stain or paint the finished column the color of your
choice using exterior-grade materials.
4. Center the brass sundial on top of the column. Use
16 brass upholstery tacks spaced evenly around the
sundial to hold it in place.
Try other exciting indoor and outdoor
projects from www.wowimadeit.com !
Figure 5
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