Creative Woodworks & crafts 2003-08, страница 30

Patterns Located in Full Size Pattern Section No. 2!

Western Stagecom

by Henry Donald Berns

SUPPLIES

Wood: basswood saw blocks or soft plain-grained wood of choice—one piece 3/4" x 1-1/4" x 10" (for the horses), one piece 1-1/8" x 1-3/4" x 5" (for the coach body), one piece 3/4" x 3/4" x 7' (for the stage driver, the driver's arms and the luggage trunks), one 1" wide x 5/16" thick stick (for wheel gluing fixture), one 3/4" thick stick (for scroll sow fence), one piece 1 /2" thick (for mounting base)

Tools: table saw for cutting saw blocks; scroll saw

capable of making 1-3/4" thick cuts; No. 5. No. 2, and No. 2/0 scroll saw blades; drill press or hand drill; 1 /8"-Dia. and 1 /16"-Dia. drill bits; awl to make starter holes for the drill bits; rotary sander (optional); small needle or riffler files

Fingernail emery boards and fine-grit sandpaper Two small C-clamps (for holding scroll saw fence stick) Package of big sewing needles to hold painted items Piece of Styrofoam to hold paint needles 3/4"-Dia. wood dowel rod (for wheels) 1/8"-Dia. wood dowel rod (for coach tongue) White glue and super glue Masking tape to cover saw cuts when doing other view cutting

Green file folder or similar stiff paper for alternate

mounting base Black fine point permanent marker pen Clear polyurethane spray to seal raw wood items Acrylic paints of choice; Black, Brown, Gray, Red, White, etc.

INSTRUCTIONS

Pattern preparation

Photocopy the patterns and cut around the rectangular outline block for each set of side/front view patterns. Note: for the coach body, the top view will not be glued on the saw block. Fold the paper on the line between the front and side views and crease the fold with the backs of the two views together. Note: the fold line for the coach body is at the front of the foot rest and at the end of the axles.

Sawing

The deep saw cuts for the coach body need to be done with a large No. 5 blade. The horses can be done with a No. 2 blade. The much smaller and detailed stage driver and luggage trunks need to be done with a much smaller No. 2/0 blade. If you have a variable speed saw, it is best to use a slower speed for these small items so you don't cut too fast and have better control. 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.

The major challenge in sawing the coach body is to keep clean, square comers and flat surfaces on the finished item. It is very important to keep the saw blade perpendicular to the saw table; it should be checked with a quality square. Be sure to keep the proper tension in the blade so it makes straight cuts in the thicker dimension of the saw block.

If the saw block for the horses is about 10" long, all six horses can be cut from the same block. Saw blocks must always be longer than the pattern being cut so as to allow you to get a good grip on them away from where the cutting is being done.

Saw out the six horses first as they will be easier to do, and allow you to become familiar with 3-D sawing techniques. Begin sawing with the side view and remove the material from between the front and back legs of the horse. Continue the sawing in the front view and remove the material from belween the left and right legs. Finish the front view cutting by going around the outside of the front view.

Continue the work on the horse by putting masking tape over the saw cuts or the front and back of the saw block. Give the sides of the block a gentle squeeze as you put the tape over the saw cuts. Make sure the bottom of the unfinished horse piece is still lined up even with the end of the saw block. It can shift up or down a small amount since it has been cut free.

Finish the side view cutting by going around the body. Fig. 1 shows a horse after sawing has been completed. The end of the saw block can now be cut and sanded square again, and the patterns for the next horse can be put in place. Repeat the sawing procedure to make six horses.

The stage driver is very small and may be difficult to saw unless you are an experienced scroller. It involves cutting the arms separate from the body. The arms are very small parts

14 • Creative Woodworks S. Crafts August 2003

continued on page 32