Craftsman Don Doyle previously appeared in the June 2004 Bulletin in an article showcasing his clock case making versatility. Don is a member of the NAWCC and Great Lakes Chapter 6. He is a retired wood model maker and specializes in clock case restoration, making reproduction clocks, and carving and creating anything made of wood. Acorn clocks are among Don’s recent creations.

Don Doyle completed nine reproduction J. C. Brown acorn clocks in November 2005.

The Clock Case

Don followed the original design as closely as possible, even locating hard-to-find Brazilian rosewood veneer, which was needed for the outside lamination on the case. Three different types of veneers, maple, mahogany, and the Brazilian rosewood, were used for the lamination. The cases were a challenge to make because of the nine-ply continuous lamination. The original cases were finished with only one joint at the very top of the case. In order to accomplish this in the reproduction cases, Don made an acorn-shaped mold, which utilized two four-ton jacks to close once the glued veneers were placed inside. The original J. C. Brown acorn clock cases were made around 1845 and were probably shaped in a mold that was pressed by steam power. These mid-nineteenth century cases were most likely one of the first applications of plywood in the United States.

The Clock Movement

To make the clocks more authentic Don purchased nine original lyre-shaped Forestville Clock Company movements. Because J. C. Brown used these movements in a few different clock case styles, they were fairly easy to find. However, the original acorn clock movement was fusee-powered and all of the found movements were not, so Don made up fusee assemblies like the original clock. He turned the wooden fusees on a lathe and then contracted a local machine shop, which used a C.N.C.-powered lathe, to make the cable grooves. He made the other necessary components, with the exception of the mainsprings and fusee arbors. The fusee arbors were machined by another local machine shop in Michigan.

Contributing Craftspeople

Other craftspeople were commissioned by Don to assist with these reproduction acorn clocks. Arnold Van Tiem, a watch and clockmaker, pre-cleaned the movements and fit new escape wheels on them, with the correct tooth count for an acorn clock. Worn bushings were replaced as needed and the pivots were polished. Rust was removed from the steel parts and the movements were recleaned. The end result was nine movements in A-1 condition.

Expert dial painter Millard Ryland was commissioned to reproduce the clock dials. Millard first prepared the zinc dial pans so that the paint would adhere. The dials were then repainted exactly as the originals.

Reverse glass painters Tom and Jan Moberg replicated the clock glasses following exactly, for eight of the clocks, the Merchants’ Exchange scene design found on the J. C. Brown acorn clock in the Henry Ford Museum. The ninth clock features a geometric design per the buyer’s request. Original acorn clocks came with painted glass featuring a variety of scenes and designs.

Don Doyle’s clocks are probably the most accurately reproduced J. C. Brown acorn clocks made. In fact, if the cases could be aged, one would think these were all original clocks. Our hats go off to Don for making another fantastic clock reproduction.

About the Author

Arnold C. Van Tiem is a full-time watch and clock repair instructor at the Career Preparation Center in Sterling Heights, Michigan. He is an NAWCC Fellow, director of Great Lakes Chapter 6 of the NAWCC, and is a director of the Research and Education Council, American Watch and Clockmakers Institute.