So yesterday we left off with a clean and reassembled mitre box with a few missing accompaniments. I was also left with a broken drill press (piss.. damn you HF!!!!!!)..
Anyhoo.. the drill press saga will come into play in a bit but first I needed to draw up some plans for the missing tree from a photo provided by a fellow LJ.
I blew it up on my computer screen till it was scale to my ruler and started mapping it out on some graph paper ending up with this..
Now…. I hear a lot of folks on here talk about working with metal as if it is a foreign subject but really it is not much different than working with wood and in some respects it’s a bit easier. No grain direction to contend with, no seasonal movement to consider and nearly anything can be fixed with some filing lol. If you own old tools you should own a few metal working tools imho.. but anyhoo.. where were we.. oh yes..
Just like if I was to cut this out of a chunk of wood I attach the plan to the aluminum block with spray adhesive.
Now I cut off the excess on the side (gonna hang onto it and use it for the flat base portion)
I put a course toothed blade on my hack saw and cut just outside the line.. NEVER CUT THE LINE!!. You want to cut just outside it and file to the line. This goes just like cutting a dovetail. Start the cut and watch the line. It will seem like you are getting nowhere at first but in no time your done!
Then I file to the line. For those who don’t know, files cut in one direction only. Don’t use it like a saw.. push lift reset push. If it starts squeaking that means it’s filled with shavings and needs a quick cleaning.
Now here is where I wish I had my drill press. I need to drill 2 5/16” holes for the rods to pass through. Would be an easy task with a drill press but.. I must have left my easy button at work or something.
I decided on a dowel jig and my corded drill for this task.
When drilling in metal faster gets you nowhere.. slow and even pressure will actually drill faster.. keep that in mind.
I drilled both holes.. Not bad..
Then flipped it over and.. well piss.. Again DAMN YOU HF!!!!
Oh well.. that one will have to be filled and redrilled when I get to braising this together. Live and learn right?
At least they line up with the base..
Next I laid out my cut lines and started cutting the rest of the rough shape out.
And this is what I have ended with for today…
Next will be hogging out the rest of the waste with some carbide cutters in my dremel, fixing a hole (darnnit) and working on the base. Hang in there.. playing with fire is coming up soon!
-- Eric - http://theidiotgaloot.com