Amazon sent me another
Dremel 4000 practically immediately. In fact, the new one arrived the day after I left the non-functioning Dremel in the hands of UPS. However, I didn't have a chance to open the box until the weekend. During the week I get home as the sun is failing, so I had to wait.
First thing Saturday, I was up and ready to test the second Dremel 4000. I had one month to send it back to Amazon if it, too, failed. According to the tool's comment section section, chances were good that it was going to fail. For all my eagerness, though, I found myself staring out the back door at the wet freezing weather. Winter had arrived once again.
I waited until after 3 p.m. to haul everything to my work table under the Bradford Pear, as leafless and stoic as the season. Extension cord, new Dremel, old Dremel accessories, sandpaper, gloves, goggles, facemask, something dry to sit on, headphones, phone. And two sticks to use as test subjects: a long, thin and relatively fresh branch of white elm and an aged branch of
juniper ashei cedar.
And by "test subjects" I mean wood I'm going to shape into wands without any prior planning. I didn't know what I was going to make, I just knew I had about two and half hours before the sun set.
Once I had the Dremel set up with the basic 40-grit sanding drum, I let it run at low speed for five minutes. That's according to instructions, to make sure all the parts were working correctly. At 3:27, the Dremel was still workiing as intended. Good to go.
First, I cut a 15-inch section off the elm branch.
The elm's sapwood was very pale, almost white. I started removing the bark and found the wood soft and sinewy, a sign that its source tree was probably fairly young. I actually knew exactly which tree it came from -- down the road, across the street, along the sidewalk -- and I'd guess it was less than 10 years old. By the look of its torn end, the branch might have been errantly pulled off or inexpertly pruned.
As I worked, I kept stopping work to turn off the Dremel, wait a moment, then turn it back on. The previous Dremel that I'd just purchased worked great for a couple hours then, when I paused to change bits, refused to turn back on again. Eventually my suspicions were confirmed that the housing beneath the on/off switch malfunctioned, a well-known issue with the Dremel 4000, for those who read product reviews.
In thirty minutes, I had removed all the bark and formed a rough hilt and shaft, with a thin cut outlining the boundary between the two. The sanding had gone very quickly. The Dremel's top speed is 35,000 rotations per minute, but I had it set at only 15,000 rotations per minute and the bit chew through the wood like a hungry dog. I was nervous to use the Dremel any further for this particular wand.
It was only 4 p.m. so I decided to continue shaping the white elm with sandpaper. The 100-grit was the perfect next step, stripping down the rough surface to expose a lightly-veined wood underneath. I progressed up through the 120-, 180- and the 220-grit sandpaper until the wand was polished smooth. I was glad that the vein lines remained, giving the wand a distinct look.
Next up was the 20-inch cedar branch. It was much thicker and harder than the elm. By then it was approaching 5 p.m., so I quickly started carving.
The cedar's sapwood peeled away easily when I ramped the Dremel up to 20,000 rpm, a much faster speed than I would normally use but I really needed to put the tool through its paces. It hadn't failed at lower speeds.
The Dremel's top speed was too much. At 35,000 rpm, the sanding bit dug into the wood like a shovel into sand, which is not useful, so used that high speed with the cutting bit to trim away the branch nodes.
Back down at 20,000 rpm, I shaped the hilt and the shaft within 45 minutes, leaving a thick ring at the top of the hilt, in case I wanted to design around it.
The cedar was 22 inches to start but I trimmed away the last five inches of the shaft that hooked to one side. I also trimmed away the ring material above the hilt, carving a long, tapering design for the wand. By 5:30, I was ready to give the Dremel a rest for the day. It continued to turn on and off without any problem so I gave it the night off. I brought out the sandpaper and smoothed the surface until sundown.
Placing the two test wands side-by-side, I realized they both had the same slight "s" shape, even though they both started out fairly straight. The picture of the two of them is in the last of the light. I'll refine their shapes during the next test, for which I'll have to wait another week. It rained the entire next day (today) and rain is forecasted to fall for a week.
Alas. At least the Dremel worked, and I have two new wands to refine.