46 American Woodturner Spring 2007

Rose-Engine
Turning
Journey into ornamental turning
O
rnamental turningOT
among its fansis
admired by many but
practiced by few. One of the
obstacles that holds turners back is
that this intriguing work requires
a rare specialty lathe.
At least it was rare until now.
All the projects shown on the
following pages were turned on a
homemade rose-engine lathe. Not
only is it easy to build, its capable
of doing precision OT work.
The four projects that follow
provide an introduction to
the rose-engine lathe and its
capabilities plus an overview of
some basic techniques.
Of course, youll first have to
build your lathe, described on page
52. A dozen AAW members have
already made these lathes, and you
can do this too!
Much of what is described in
these pages will be obvious the first
time you turn the crank on your
rose engine. But until you actually
see it happen, text descriptions
cannot do it justice. The magic of
how a rose engine works and what
it does is something that has to be
experienced.
A rose engine differs from
other lathes in many ways, but
the biggest difference is that
the headstock is not stationary.
Instead, the headstock is hinged,
allowing it to pivot back and forth,
called rocking. By controlling this
rocking motion with a rubber
riding against a rosettea
cam-like diskyou can cut
countless patterns.
Another distinction is that,
unlike regular turning, rose-
engine turning is usually done
with a motor-driven fly cutter,
known as a cutting frame. By
hand-cranking the lathe, the turner
rotates the piece slowly past the
cutter. The most common cutting
frame, a horizontal cutting frame,
is a tool supported on some sort of
slide rest, which has a fly cutter
rotating in a horizontal plane. The
cutter is spinning at high speeds
similar to router speedsand
taking light cuts on each pass.
For more help with terminology, see
the photos opposite and on page 52.
To see a video clip of a rose engine in
action and for more OT history, visit
the AAW website at woodturner.org.
Get started
When first becoming familiar with
your rose engine, you may want
to devise some sort of a paper
chuck, as shown in Photo 1, which
is useful for drawing the patterns
and helping understand what the
rosette, shown in Photo 2, will
By Jon Magill
Instead of admiring
ornamental turning,
its time you give it a
try. Here is an easy
and inexpensive way
to start, including
details on how to
build your own rose-
engine lathe.
Reprinted with permission.
American Association of Woodturners
47 woodturner.org
produce. Generally speaking, the
features or bumps on a rosette
produce more pronounced effects
as the diameter of the cut or
pattern decreases.
Of course the best way to learn
what a rose-engine lathe can do
is to just start making test cuts, as
shown above.
A note on safety: Be careful and
aware of the fly cutter on any OT
cutting frame. The cutter spins
so fast that it becomes invisible;
you need to consciously resist the
temptation to put your fingers
anywhere near the cutting frame.
Limitless patterns
All the photos and
projects on these pages
were made using just
two rosettesone with
four bumps and one
with 24 bumps. The
four-bump rosette looks
like a puffysided square.
The bumps on the other rosette,
as shown below right, look like a
sine wave pattern of 24 bumps
around its edge.
In addition to the patterns on
the rosettes themselves, there are
two added features that serve to
multiply the pattern possibilities
a fading stop and phasing. Used
in various combinations it would
take a lifetime to exhaust just the
possibilities of these two rosettes
alone. The fading stop works
by limiting the headstock travel
when it is rocking back toward the
operator. The effect of the fading
stop is seen as sections of smooth,
circular cuts between the portions
of cut produced by the bumps
on the rosettes. Like much of the
rose engine in general, this will be
much easier to understand once
you have seen it in action.
To begin exploring the
capabilities of your
rose-engine lathe, make
sample cuts. These were
turned from 3"-diameter
maple stock.
All the projects in this article
were turned with this homemade
rose-engine lathe.
1
2
With the brass pin placement, the turner
alters the phasing of the rosette, which
creates different effects.
To explore patterns created by a rosette,
hold a sheet of paper on a at surface
mounted to a faceplate on the spindle. Then
place a felt-tip marker in the tool holder.
Main pulley and rosette
(rubber on T-track hidden)
Rocking headstock
Spindle (1"-8)
Bungee adjuster block on T-track
Adjustable fading stop
Hand crank
48 American Woodturner Spring 2007
Two basic cuts
There are two basic cuts when
turning with a rose engine, and
the effects are markedly different.
Cuts are either made on the face
or the side of a workpiece. The
differences will come into play
when you begin designing your
own OT projects.
Face cuts are made with an
arcing movement of the headstock.
In general, they tend to be shallow
with interesting effects at their
near and far edges. The arcing
movement of the headstock tends
to wash away details at the center
of most cuts. Face cuts are often
done as a series of concentric cuts
with some space between them,
allowing the edge features to meet
at the ridges between each cut in a
series. This will make more sense
once you actually try it.
In contrast, side cuts are
plunging cuts. The rosette allows
the cutter to plunge into the
work and then pull it back out.
The depth and effects are quite
different from those of cuts on
the face. Two techniques are used
to progress the side cuts along
a piece: Simply move the cutter
along, creating straight flutes or
grooves, or you can phase the
rosette while making a series of
cuts. This second technique of
phasing can produce effects like
spirals and chicken wire, as shown
in Photos 3 and 4.
Last but not least is the
surprising effect of where the
cutter is actually positioned. If the
cutter is located on the operator-
side of center, the pattern produced
will mimic the shape of the rosette.
By simply moving the cutter to the
other side of center, the rose engine
will invert the pattern of the
rosette, often with surprising and
pleasing results. Youll read more
about this effect on page 50 in the
square-knob details that follow.
Wood selection
Because OT is less forgiving
than plain turning, choosing
your turning stock is key. Select
hardwoods that are as dense
and as close-grained as possible.
Sanding is generally not possible
after cutting; the finish cut your
tool produces is critical.
A wood that is dense enough
to show the pattern is important.
That said, while you are learning
and discovering the endless array
of possible patterns, almost any
hardwood will work. Eastern
maple is a relatively inexpensive
wood good for experimentation.
Knobs
Turning knobs for cabinets or
drawers is a simple, repetitive
project that will require you to
keep track of your rose-engine
settings to get matching results on
duplicate parts.
Start by making the blanks and
3
4
A simple spiral pattern emerges by phasing
the rosette with each subsequent cut.
This chicken wire pattern is created by
alternating the phasing forward and back
with each cut. Each row of diamonds
represents one revolution of cutting.
Purse mirror
A purse mirror is a good first
project that you can accomplish
using mostly face cuts. Mirrors
come in various sizes (2" and 3"
diameters are popular) and require
about a "-deep recess.
Mount a round blank 2" to 4"
in diameter (depending on your
mirror) onto your regular lathe
and turn a recess to accommodate
your mirror. The mirror at right
was turned with European plum.
Mount a wasteblock slightly
larger in diameter than the recess
you just turned. Make a jam chuck
and reverse the mirror blank onto
the jam chuck.
If you havent already done so,
try some sample cuts to get an idea
of the basic patterns you like.
Now, move the blank over to
the rose engine and cut a pattern
based on your plan, as shown in
49 woodturner.org
inserts. Most cabinet knobs use #8-
32 threads for the screws.
Make a wasteblock to
accommodate your fastener, as
shown in Photos 7 and 8.
Mount each knob and turn down
the shoulder on each knob as a
first step, as shown in Photo 9.
This is done by centering the rose-
engine headstock and backing off
a mounting jig for turning them.
For cabinet knobs, 1
1
/
2"-diameter
blanks about 1
1
/
4" to 1
1
/
2" long
seem to be about the right size,
but your design may dictate other
dimensions. Either drill and tap
your wood and harden the threads
with cyanoacrylate (CA) glue or
drill holes in the blanks large
enough to install brass threaded
9 7 8
5 6
Photo 5. After you have made a
few mirrors, you might want to
try decorating the face and edge
of the blank, as shown in Photo 6.
Decorate the edge using the rose
engine after turning the mirror
recess but before reversing onto
the jam chuck.
Next, reverse and jam-chuck to
cut the pattern onto the back.
Although a simple project, this
should give you a feel for moving
back and forth between your
regular lathe and the rose engine.
Before reversing and jam-chucking,
decorate the edge of the mirror case.
A purse mirror will give you your
rst taste of accomplishment
with a rose-engine project.
Cut the pattern for the back of the purse
mirror.
Drill the knob blank to mount on the waste-
block. Harden the wood threads with CA glue.
Turn down the shoulder of each knob. A belt-
driven cutting frame, left, does the work.
Drill and tap the wasteblock. Secure an #8-
32 screw from the backside with CA glue.
50 American Woodturner Spring 2007
the rubber so that a round cut is
produced. You can make a pair of
centering wedges for this purpose;
slip one in front of and one behind
the headstock.
For the next steps, you need to
mount and complete each knob
without removing it. Cut the edge
of the knob to a depth that pleases
your eye or meets your design
criteria. Write down the location
of your slide rest so that you can
return to this depth of cut for each
subsequent knob, as shown in
Photo 10.
Now, move the cutting frame
around to the front of the knob
and make the face cuts to finish
the knob, as shown in Photo 11. As
before, establish a way to record
your slide rest locations so that you
can duplicate the pattern later. If
your slide rest has a provision for
stops, that may make it easier to
repeat your cuts up to the stops,
maintaining locations and depths.
You should see the effects of the
fading stop employed in both knob
designs. Without the fading stop,
the squarish knob would have
been perfectly square around its
periphery. Likewise, the round knob
would have had a sine wave pattern;
instead, the fading stop produced a
series of ribs around its edge.
If you have built your rose
engine and are experimenting
with it, you will recognize the
other effect on the face of the
square knobcutting on the near
and far sides of center. The four-
sided rosette used for the square
knob will cut a square or pointed
pattern when the cutter is on the
operator side of center. When the
cutter is on the far side of center,
you produce a cloverleaf-like
pattern of four rounded lobes. This
surprising inversion works with
every rosette and often creates
very striking contrasts.
The square knob shown in Photo
11 also incorporates phasing,
which allows the points to fall
into the middle of the rounded
cloverleaves.
Setup hints
Here are some hints that will help you get up and running successfully with your rose engine:
To speed the process, pre-turn waste areas on your regular lathe.
Adjust the rubber so the headstock oscillates almost vertically in its travel.
Ensure that there is just enough bungee tension to maintain rubber contact.
Adjust center height with trial cuts on scrapwood; check the work with a magnier.
Adjust the fading stop and check nut to lock in position.
To minimize dust, set up a vacuum nozzle near your cutting surfaces.
Before cutting, check that your project is within the travel range of your slide rest.
Add a drop of oil on the rubber/rosette to help things glide along.
Before bringing in the cutter, crank the workpiece so that it is moving.
To reduce burn marks, back off the cutter before stopping.
11
10
Tool handle
A tool handle is a simple project
on which to experiment with rose
engine turning on the side of a
workpiece. This project blends
Alan Lacers tool handle process
(Winter 2004 American Woodturner)
with Bonnie Kleins technique of
using a
3
/
8" brass compression nut
for the ferrule and turning off the
flats of the nut as a last step. This
project has also been adapted to
Make the decorative cuts on the face of
the knob. Notice how phasing was added
to position the points of one pattern in the
rounded lobes of another.
Turn the edges of the knob.
51 woodturner.org
13
12
14
15
16
work with an interchangeable-
tip screwdriver holder (Rockler
is one mail-order source). Most
interchangeable-tip screwdriver
holders have
1
/
4" hex shanks, which
can be driven into a
1
/
4" diameter
hole. Eastern maple is a good
choice of wood; it is hard enough
to stand up to use and it takes the
ornamentation well.
Mount a blank between centers
and turn a tenon and shoulder to
mount in your chuck. Mount the
blank into your chuck and put it
back between centers.
Cut a tenon on the tailstock end
of the blank to accommodate the
interior dimensions of the
3
/
8" brass
compression nut, as shown in
Photo 12. Thread on the nut tightly
against the shoulder, then trim
any excess wood. Match a bit for
the tool-holder shank, then drill as
deep as the length of the shank, as
shown in Photo 13.
Drive the screwdriver shank
partially into the blank and add
a dab of thick CA glue to the
shanks groove. Finish driving
the shank until it bottoms out on
the compression nut, as shown in
Photo 14.
Secure the screwdriver holder in
a chuck and mount it on the rose
engine. To prevent the chuck jaws
from marring the surface, wrap the
holder with a layer of aluminum
foil. Start cutting your pattern at the
headstock end, as shown in Photo
15. Cut to your desired diameter.
With your slide rest set at an
angle you like, work your way out
along the handle at an appropriate
taper, as shown in Photo 16.
Unlike plain turning, the rose
engine takes such light cuts that
you can usually get away with
cutting techniques like cutting
away from an already thinned
section, which wouldnt work on
a regular lathe. (For longer work,
some of the antique rose engines
included a rocking tailstock to help
support the piece.)
Continue to work your way out
slowly to avoid leaving visible
ridges between your successive
cuts. The fading stop creates ribs
instead of the sine wave that the
rosette would have created if left
unaltered. Work your way around
the butt end of the handle and cut
a decorative pattern on the end.
Check the diameter of each compression
nut, then cut the tenon to t the interior.
With a belt-driven y cutter, make your
ornamental cuts at the headstock end.
You can design and turn the entire handle
on the rose-engine lathe.
Insert the tool-holder shank and adhere
with CA glue.
Drill the handle to the depth of the tool-
holder shank; most shanks are about 1".
52 American Woodturner Spring 2007
R
eady to dive into
ornamental turning? Before
you can begin, youll need
a rose-engine lathe.
Get started on building your
own rose-engine lathe with a
plan modified from a design by
Paul Fletcher, an accomplished
and ingenious ornamental turner
from the United Kingdom. Pauls
original design was based on
cutting all the pieces from a
half-sheet of " medium-density
fiberboard (MDF). With Pauls
permission to publish his ideas,
the design has been updated to
streamline the construction and
to incorporate as many standard
parts as possible.
This simple plan for a rose-engine
lathe is capable of doing precision
work, yet it is easy to build in a
home workshop. A number of
machines have been built, and feed-
back has continued to improve the
design. More are being built every
month. A kit, including machine
parts (see opposite), makes it easier
for anyone to build their own.
Bonnie Klein and her husband,
Robert Purdy, built one from these
plans. Weve been experimenting
with rose-engine work for nearly
10 years, Bonnie said. We are
amazed at the capabilities and
potential of this fascinating
machine. This homemade lathe
offers exciting new opportunities
for creative and artistic expression.
It will be interesting to see rose-
engine turned pieces in future
AAW Instant Galleries.
Whats involved
The basic rose-engine lathe will
get you started on the journey
to enjoying ornamental turning for
an investment of $250 to $300 in
materials and machined parts.
The rose engine consists of a
base and a rocking headstock.
The headstock is hinged on a set
of simple, adjustable pivots below
the table surface. A spindle passes
through the headstock and runs
in bronze bushings. The outboard
end of the spindle has a flange
to mount a turned pulley, which
in turn holds a rosette. Another
step-up pulley carries the belts
that go from the spindle pulley to
the hand-crank pulley. An upright
supports two pieces of T-track. One
19
Square-lidded box
Perhaps the most intriguing
quality of the rose engine is its
ability to produce work on a lathe
that is not round. Instructions
for making a box like this would
require an entire article, as well
as a few tools you might not
have when just getting started
with your rose engine. But rest
assuredthis box was made
entirely on the homemade rose-
engine lathe described at right.
Jon Magill ([email protected]) is an
ornamental turner who lives in Clinton,
Washington. Jon is a member of the
Seattle Chapter AAW and Ornamental
Turners International, an AAW chapter
dedicated to ornamental turning. Jon
will present sessions on building and
using the rose-engine lathe at the AAW
symposium in Portland.
Build Your Own Rose-Engine Lathe
Main pulley and rosette
Bungee adjuster block on T-track
Adjustable fading stop
Hand crank
53 woodturner.org
T-track holds the rubber, which
rides against the rosette; another
holds the block that adjusts the
bungee cord that supplies tension
to the headstock.
Once you have all the
parts, it should take about
two days to cut, glue,
and assemble the entire
lathe. If you or a friend has
a metal lathe and mill, you
should be able to easily make
the seven machined parts for
the rose engine. Or, use our kit
source (supplied with website
plans). Consider this lathe an
affordable platform to begin
exploring ornamental turning. If
there is sufficient interest from
AAW members, follow-up articles
can describe advanced capabilities
already designed to be added onto
this rose-engine lathe.
There are few critical dimensions
in the design of this homemade
version. However, before you
start experimenting, you should
consider building one as close
to these plans as possible: Many
subtle aspects are not obvious
until you have used a rose engine.
Once you have used the lathe and
understand how it works, modify
the design to suit your needs.
The plans for the lathe (see
below) include details to allow
phasing of each rosette, as well as
the adjustable fading stop for the
rosettes. These two simple features
open up the pattern options that
you can produce on your rose-
engine lathe.
In addition to building the
basic lathe, you will need to build
or buy some type of slide rest
to manipulate the cutting tools
around your work. And finally,
you will also need at least one
cutting frame to do the work. The
plans include some options for
both of these.
Jon Magill
Build Your Own Rose-Engine Lathe
Rocking headstock
Spindle (1"-8 tpi)
Used compound from metal lathe
Tool post to hold cutting frames
Plywood base for compound
Rosette mounted on main pulley
Rubber on T-track
Holes and pin for phasing rosette
Spindle end and main ange
Rosette-mounting thumbscrews
Hand-crank pulley

5
/ 16" round V-belt
Step-up pulley
End of headstock pivot with shaft collar
AAWWEB
Free plans on AAW website The complete
step-by-step plans, construction drawings, parts
list, sources, and details about a parts kit for
the rose-engine lathe are available free to AAW
members at woodturner.org