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Pie Crust Table #6: The top is finally done!

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Blog entry by GaryK posted 05-10-2009 09:56 PM 2324 reads 1 time favorited 24 comments Add to Favorites Watch
« Part 5: The edge completed! Part 6 of Pie Crust Table series Part 7: The column »

I guess I used this step as a lesson to myself on how to remove a lot of material fast. Having never done anything like this before I thought I would try different methods.

The first method was route channels leaving some uncut material to support the router and then use my flush cut saw to remove them. Then I thought of all the dust that would make so I tried to make a bunch of saw cuts and beat them out with a hammer. This worked very well at limiting the amount of chips.
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But when I used the router I was scared to death of slipping near the and ruining the entire thing.
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Then I tried to use a stationary router in moving jig. This is the jig that I used to flatten my work bench.
But once again I was afraid when I got to the ends because I was cutting blind.
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This is the method I ended up using. A stationary jig with moving router. It was very effective and relatively fast.

I made it with hardwood sides the keep it from drooping in the middle and melamine to reduce friction. Another thing I did for safety was to install stops. One on each end to limit the travel of the router and in the lower picture to keep the jig in position.

I just lined it up in the center and made a cut and then rotated the jig around the center point looking through the slot to position it. I also used an old candle to wax the bottom and edges or the router to make it slide very easily.
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The slot was about 2” wide allowing me to make two passes, with the 1 1/2” bottoming bit I used, before re-positioning the jig. One half a rotation of the jig and I was done with the first pass. I took about 1/4” of material off at a time.
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It ended up taking me about 1/2 an hour of cutting to complete it.
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After a little sanding with 40 grit
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And Last but not least 1/2 of the pile of wood removed with router. That’s an 18” scale.
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Next time I will start with the stand. Like I said in the beginning it will be something different.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX



24 comments so far

View cobra5's profile

cobra5

154 posts in 2724 days


#1 posted 05-10-2009 10:12 PM

thanks for the inspirations,

-- tool time tim aka "cobra5"

View Rj's profile

Rj

1047 posts in 2386 days


#2 posted 05-10-2009 10:14 PM

Wow Gary That looks great! it will be exciting to see it when your finished .

Thanks again for filling us in on the process . (I’m learning alot from your posts)

-- Rj's Woodworks,San Jose & Weed Ca,

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 3054 days


#3 posted 05-10-2009 10:15 PM

That’s sure going to be a beautiful table.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1

View a1Jim's profile

a1Jim

112943 posts in 2332 days


#4 posted 05-10-2009 10:15 PM

Very nice Gary looking forward to more progress

-- http://artisticwoodstudio.com Custom furniture

View lew's profile

lew

10168 posts in 2510 days


#5 posted 05-10-2009 10:22 PM

Gary,

Thanks for sharing the trip to what is going to be one beautiful table!!

Lew

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View tenontim's profile

tenontim

2131 posts in 2499 days


#6 posted 05-10-2009 10:31 PM

This has been a very informative series, Gary. I can’t ever see myself making this style of table, but the methods that you used are very interesting. Hopefully they’re filed away in the brain bank and can be retreived at a later date. Thanks for all of the post on this.

View Scott Bryan's profile

Scott Bryan

27251 posts in 2577 days


#7 posted 05-10-2009 10:33 PM

Your ingenuity and resourcefulness never ceases to surprise me. Many of us, I know I would fit in that category, would have settled on a removal technique at the start of the process and doggedly stuck with it rather than stopping midstream to evaluate things and try to come up with a more effective process. And building a jig in the middle of things!!! That interruption only slows you down- right?

Nice job, Gary. Thanks for the post.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View pommy's profile

pommy

1697 posts in 2446 days


#8 posted 05-10-2009 10:51 PM

as always gary you look at the bigger picture i was talking to fellow lumberjock on saturday ( philip edwards )at a local wood show
and i told him how wonderfull i think your work is thank you for show us mear mortals how to do things properly

andy

-- cut it saw it scrap it SKPE: ANDREW.CARTER69

View DocK16's profile

DocK16

1140 posts in 2842 days


#9 posted 05-10-2009 10:57 PM

I have been waiting for each episode to be posted since you announced the project. Several good ideas to hog out the waste but the final method I think is the best. Can’t wait to see the base I’m sure you won’t disappoint.

-- Common sense is so rare anymore when you do see it, it looks like pure genius.

View Napaman's profile

Napaman

5365 posts in 2832 days


#10 posted 05-10-2009 11:11 PM

wow…that is amazing…you said half an hour—-for all methods??? that seems fast…amazing..

-- Matt--Proud LJ since 2007

View Joe Lyddon's profile

Joe Lyddon

7952 posts in 2807 days


#11 posted 05-10-2009 11:33 PM

Hi Gary,

Very good progress!

I’ve gotta say… when I saw that circular saw cutting slits, my first thought was “Oh No!”... I was happy to see how you modified your method.

Your final solution is very similar to a fixture I made called Router Skiis. For the average project, it works pretty well.
See more about it at… http://www.ncwoodworker.net/pp/showphoto.php?photo=24057

Your Top really turned out GREAT! Thank you for the progress reports!

Now, for the part that holds it up! :)

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View SCOTSMAN's profile

SCOTSMAN

5594 posts in 2340 days


#12 posted 05-10-2009 11:40 PM

Great Job as usual gary well done laddie Alistair

-- excuse my typing as I have a form of parkinsons disease

View Karson's profile

Karson

34916 posts in 3155 days


#13 posted 05-10-2009 11:42 PM

Can you take the chips back gary and ask for your money back. Tell them it was not needed.

Great job on the flattening. and removing.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View Lee A. Jesberger's profile

Lee A. Jesberger

6704 posts in 2734 days


#14 posted 05-11-2009 12:14 AM

Hi Gary;

I’ve been watching with interest in how you did the top. As usual, your work is Masterful.

Hollowing out the center is a scary process, huh?

A suggestion if you don’t mind. If you are going for an 18th century look, the outside or “crust” looks a little on the bulky side.

That has a lot to do with our decision to carve the edges, when we were building one:
http://lumberjocks.com/LeeJ/blog/1628

Great work!

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

View CanadianWoodChuck's profile

CanadianWoodChuck

395 posts in 2668 days


#15 posted 05-11-2009 12:24 AM

Excellent progress report Gary – it will be beautiful. I love your flattening jig. Thanks

-- Wood Chuck (Bruce) http://3dwoodworkingplans.com

showing 1 through 15 of 24 comments

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