I am not sure why exactly I decided to carve this knotted Star of David pendant, but it is my favorite style of the Jewish Star. I first noticed the knotted Star of David on a tattoo and it has stuck with me since as the most striking iteration out there.
As always, the project started with a 3D model in Solidworks (see on Grabcad). I used Sapele wood left over from my Christmas Box project. Sapele is one of the few lumbers with the strength to hold together with such narrow walls, and has a grain that I thought would age beautifully around the neck without lacquer.
I didn’t use too many tools to make this. I first traced the shape on to the wood, then rough cut the shape on my band saw. The Sapele I have is inch thick rough cut, so I then split the rough shape in to two half inch stars, again using the band saw.
Oddly, I put my smallest straight router bit in to my drill press and used it like a router to open the inner spaces of the star as much as possible before filing and carving.
I brought all of the inner spaces and the outside edges of the star to size using a simple set of files from Harbor Freight. This was a slow method, especially on such dense wood, but it was an excellent way to occupy free time.
After bringing everything to shape the knotwork was a bit touch and go before getting down a reliable method. Ultimately, I used a piece of saw I broke off of a hacksaw blade to first groove the deepest part of the knot, then used a carving knife to shape the slope of the knot.
This experience prompted me to discover and purchase a Micro-Mark Micro Saw Set. I did not get to use it on this project, but it cuts through the hardest woods like butter. Great tool to have!
