Creative Woodworks & crafts 2003-06, страница 36

SUPPLIES

Wood: basswood saw blocks or soft plain-grained wood of choice—one piece 3/4" x 1 -3/8" x 5" (for the ox bodies), one piece 1-1/2" x 1-1/4" x 5" (for the wagon body), one piece 3/4" x 3/4" x 4" (for the wagon seat and ox tails) Tools: table saw; scroll saw with No. 2 and No. 5 blades; drill with small diameter drill bit to match the round toothpicks used for the wagon tongue; awl to make a starter hole for the drill bit; rotary sander (optional); stationary belt sander 5/8"-Dia. x 8" long wood dowel rod for the wheels Round toothpicks for wagon tongue 3/4" x 2" stick about 15" long for scroll saw fence 1 /4" x 3/4" x 3" strip of wood for wheel gluing fixture Manila file folder for canvas top Green file folder or similar stiff paper for mounting base Sandpaper, assorted grits Fingernail emery boards and clippers Small needle or riffler files Two C-clamps to hold fence on saw table Super glue for the ox tails, wheels, wagon tongue, etc. White glue to attach patterns to saw blocks Masking tape to cover front view saw cuts when

doing side view cuts Clear polyurethane spray to seal raw wood items Long sewing needles

Acrylic paints of choice—Black, Brown, Gold, Ivory,

Reddish Brown, White, etc. Black fine point permanent pen

Patterns Located in Full Size

Pattern Section No. 2!

The Conestoga Wagon

By Henry Donald Berns

36 • Creative Woodworks & Crafts June 2Q03

INSTRUCTIONS

Block preparation

This is a typical 3-D scroll saw project and will require rectangular saw blocks for the components. These blocks will need parallel sides and one end cut perpendicular to the sides. They can be made by using a table saw with a fence. It will be helpful to have a stationary belt sander to get the sides and ends of the blocks smooth and square. Basswood is recommended for wood blocks. Other soft plain-grained woods could be used. The blocks need to be at least several inches longer than the pattern area so there is sufficient length to hold the block while it is being cut. Usually the front view of the item is cut first, and then masking tape is put over the saw cuts to hold the block together while the other view is cut. To use the same block for a second item, cut and square the end of the saw block so the patterns can be glued on again.

Pattern preparation

Photocopy the patterns at 100%. Cut around the rectangular outline block for each set of side/front view patterns. Fold the paper on the line between the two views and crease the fold with the backs of the two views together. Note: the fold line for the wagon body is at the front of the wagon floor. (This is to keep the size of the saw block smaller.) Open the fold in the paper so the front and side views are at a 90° angle. Check the 90° folded pattern set on the saw block to be sure it fits properly. The bottom of each view should match the squared end of the saw block, and there should be about 1/16" of material outside of the item being cut at each edge of the block, except for the side view of the wagon body. This material is needed to hold the block together until the sawing is completed.

Open the pattern set up flat and lay it face down on a bigger scrap of paper. Put white glue on the rear of the patterns and spread the glue around with your fingertip. Excess glue can be pushed off onto the paper scrap. Refold the patterns to the 90° position and place on the saw block. Fig. 1 shows patterns glued on the three saw blocks for the wagon body, an ox body, and the ox tails. Make sure the pattern edges are in line with the edges of the saw block and match the end of the block.

Sawing

Sawing is done with a No. 2 blade in the typical 3-D fashion. One view of the item is cut first, and then masking tape is put over the saw cuts to hold the block together while the other view is cut. For the ox body, cut the material away from between the