So the tools are prepared, now the materials.
I would love to have used Bloodwood, not so easily available here, so its Padauk (I’ll watch it darken with age), Sycamore and a small piece of African Blackwood I had left from the Italian Restaurant box. To mark out the pieces I printed off the pattern and cut it up. The marking up of the Blackwood reminded me of when I was a small child, watching my mum marking out patterns for clothes (she was a seamstress).
I cut these pieces on the bandsaw and arranged them on the Padauk for a rough idea of what I’m aiming at.
For sticking the pieces to the router template I use double sided tape. Hold well enough and cleans off relatively easily afterwards.
The post on the main jig is only 15mm high. I want to route 20mm thick pieces so I taped two scraps of the sycamore (with suitably bored 6mm holes) onto the template.
To locate them properly over the pivot hole I inverted the template, put it over the pin and taped the spacer onto the underside.
I use a 6mm spiral cut bit for this kind of work. I tried a test piece, lining it up over the scratched pattern of the template, setting the bit distance from the pin to coincide with this line and taping it down.
Here’s the template on the jig, complete with spacers
I cut 2mm (height) at a time in order to give the tape a decent chance at holding and not to overload the router bit.
When I cut using a template like this I only cut up to about a veneer’s thickness away from the template face in order to save scratching it up. I remove the piece and trim the rest of with an X-acto knife.
The order of edges cut was as follows. All like pieces were cut at once and the order gives the minimum number of router bit distance re-settings in order to cut down on errors.
Half way through
Finally I have all four pieces fitting together and can rout the last two outside edges (5 in the cutting order diagram)
Right, apart from trimming up the straight edges the pattern is done
I’ve also book-matched the Padauk for the pattern surround. With the appropriated jaws my router table doubles up as a cramping jig for board glue-ups
Thats it for today. Beer time.
Be seeing you.
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com