Popular Woodworking 2006-08 № 156, страница 77
I printed nested corner patterns on standard copier paper after generating them through the CAD software on my computer. The same accuracy, however, is achievable by using a square, a dime-store compass and a ruler. A Whole Bunch of Holes With a 17/64" brad-point bit secured in your drill press, drill the four registration holes in each of the radial corner segments. Four holes may seem excessive until the segments fall prey to the flush-trimming bit. It's amazing how a little cylinder of metal, with two innocent-looking cutting edges, can exert enough force to bend 3/4" plywood as if it were overcooked spaghetti. I tried to get by with only the two inner holes and ended up with chatter marks at the unsecured extensions of the arcs. Rack of Ribs You know that I'm a band saw guy if you've seen any of my previous projects. There's something about becoming "one with the blade" and tracking a cut V32" outside of a line that gives me repeated doses of obsessive/compulsive satisfaction. So much for my problem. Your task will be to rough-cut 36 arcs out of a rectangle. After nesting your patterns on the stock to minimize the waste, start rough-cutting slowly and carefully, staying just outside the lines. You'll have the rhythm in no time. A Passion for Sanding? Pattern routing the corner segments isn't really necessary if your idea of the perfect day in the shop is one devoted to sanding. If that doesn't float your boat, read on. The router-table j ig that I made for handling these small parts consists of a rectangle of 3/s" polycarbonate plastic, two purchased j ig handles, one finely tuned pattern, This obligatory "Man Drills Holes In Board" shot is here to remind you that accurate drilling, with a backup scrap to prevent tear-out, is key to a number of forming and glue-up steps. A 17/64" brad-point bit clears the way for the V4" registration dowels. Nesting the patterns for the corner segments produces a m inimum amount of waste. Make the cuts just outside the lines. You'll be a band saw master by the time you get to your 36th smiley. popularwoodworking.com I 75 |
