Really cool and nice looking and I love the way you hid the glue joint, what's the size of it. The daughter of a friend of ours is due in late Aug. and I may try to make one of these for their grand baby because the popcorn is a great idea.Wizzy
Hi Mike. The size of the largest part is about 1 3/4", large enough to satisfy the Consumer Product Safety Comission requirements for choking hazards. The thinner you turn it the better (and easier) it will rattle, but the harder it is to burn the glue joint without cutting through it. I like to keep mine between 1/8" to 1/4" thick, and I use 5-6 popcorn seeds inside. More than that and it doesn't rattle very well. I also don't use a finigh, since it will almost certainly end up in a kid's mouth. Obviously I sand it quite fine (600).
This really is a fun project. I make a lot of these. I always have some on hand to give to wife for baby showers, and I also donate a lot of them to places like the salvation army, homeless shelters, etc.