Last night I made the master template. I have been thinking for a long time about how to do this. I thought I would need to chuck up the drum sander on my RAS but it turned out to be much easier than that. I started out with two pieces of hardboard the same width and length as the front lower stretcher. I could have chosen any rail. That was a random decision. I didn’t have the camera last night so here is a little after the fact photography.
I marked the first hardboard piece using my sketchup model as a reference. All of the cloudlifts on this project are 3/8” deep but the length and direction varies.
I marked a 3/8” line with my marking gauge along the hardboard then made another line where the center of the cloudlift will be. I drew a “fair” curve there with a pencil.
I set up the fence 3/8” from the router bit. The bearing is above the work so it doesn’t touch. Then, starting from the left, I routed the dip out til I got to where the lift starts.
When I got to the fair curve I lifted the right side from the fence still moving left to right and trying to follow the curve. It worked! I was very happy with the appearance of it. I didn’t need to fiddle with it at all. Yipeeeee!
I don’t have a picture of the next step but here is the idea. Now that I had defined my lift. I needed to get it’s mirror image on the other side of the hardboard. To do that I carpet taped the piece I had just shaped to the second piece I started with. Then I duplicated it. This left me with two pieces that had only one fair curve. Next, I simply flipped them, re-duplicated them and that completed the master. The rest of the pieces were made by taping the master in various positions on more pieces of hardboard. Here are various shots of that operation.
The rectangle is where the waste will be removed.
Line up the mark from the master with the one on the part you are making. Tape them together and rout one side. Then do the other.
Here is the bottom cloudlift. Just flip the master.
Here are all the finished templates.
And here are the finished rails dry fitted.
Thats enough for today. I think I’ll have a beer. I deserve it <o>
-- Scott - Chico California http://chicowoodnut.home.comcast.net