Here is what I woke up to. You can clearly see where I cooked it a little to much in the red. You can also see where I tried to pop a bubble on the green. Luckily it is over the wood that will become the horn.
I grab my trusty new bosch random orbital sander, which I love, throw on a slightly used piece of 80 grit. It was a piece I used for the sculpted box on my other blog, the edge was ate up but the flat of the disc hadn’t been touched. And I got nowhere. It seems I have about 1/8 of an inch of epoxy, maybe thicker in some places.
I sanded on it for about 5 mins and decided I was moving way to slow. So I went over to my planer and being very careful that I didn’t touch the tape or wood, gave it a couple of passes. I know this probably isn’t good for my blades, but it’s about time to replace them anyway. If you look carefully you can see flakes of epoxy laying on the face.
This left me maybe a 1/16 above the level of the wood. With the 80 grit on my orbital it only takes a few minutes to get it down level with the surrounding wood.
Here you can see it with the overlay on it. I still haven’t figured out how I am going to transfer it. I am about to head back out to the shop after lunch with my daughter and try to figure it out. 
Here is the original drawing just as a so you can see them together
One last note:
This is where I would normally mix up more epoxy the same color and I started with and fill in any voids left by air bubbles. I am not doing it now for two reason, one is that there are not that many and second it that I will be routing out some of the epoxy for the rest of the details. Hopefully this won’t come back to bite me. We will find out.
The next episode will hopefully be today or tomorrow. If I decide to get carbon paper it may not be up till Monday, but never fear, it will be up soon.
Any questions or comments or ideas are welcome as always.
Thanks
Joey
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks
9 comments so far
Karson
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34370 posts in 2572 days
#1 posted 504 days ago
Joey: That’s looking great.
-- 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 †
SPalm
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4118 posts in 2053 days
#2 posted 504 days ago
Neat.
I would think that a router on some rails would level that pretty well too.
It will be interesting to see how it comes out.
Steve
-- -- I'm no rocket surgeon
Eric_S
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1522 posts in 1367 days
#3 posted 504 days ago
Thats, going to look great when it is finished Joey. I’d go with steves suggestion of using a router on rails, your going to be destroying those blades on the planer. I posted a simple router planer recently on my projects, very easy to make and use.
-- - Eric Indianapolis, IN
JoeyG
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1161 posts in 797 days
#4 posted 503 days ago
That’s a great idea with the router. I’ll have to make a jig for it. I need to replace my blades anyway so I wasn’t to worried about it. I’ll be replacing them soon, so a jig will probably come after I finish this one. Thanks for the idea, I would have never thought of it. It’s always the obvious ones we miss.
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks
jaykaypur
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2501 posts in 579 days
#5 posted 503 days ago
Amazing work!
-- Use it up, Wear it out --------------- Make it do, Or do without!
gfadvm
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6650 posts in 861 days
#6 posted 503 days ago
Joey, That is coming along really well. I too have run some stuff through my planer it wasn’t intended for but I have found that it doesn’t hurt the blades nearly like I thought it would. Now dirt and the finish on prefinished wood flooring will kill blades FAST so I don’t do that anymore. Do you feel like the epoxy hurt your blades?
-- " I'll try to be nicer, if you'll try to be smarter" gfadvm
JoeyG
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1161 posts in 797 days
#7 posted 503 days ago
Hi gfadvm, glad to hear I am not the only one to abuse my equipment a little. I don’t think it did much to the blades. It may have dulled them a little, but that’s about it. I am more worried about milling up a batch of wenge than I am about that little bit of epoxy. I have used my chisels before and haven’t notice any damage or undue dulling of them. I don’t like to do that though. I gouged a piece pretty good when the epoxy chipped and try to stay away from the chisels.
I will agree with the old flooring. It is designed to be hard. I usually take a card scraper to something like that.
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks
gfadvm
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6650 posts in 861 days
#8 posted 503 days ago
Joey, You gotta get a drum sander. I now have 2 (a 10” and an 18”). They are the answer for highly figured wood and other stuff you are worried about wrecking with the planer. I looked on CL for 2 years and never saw one, then a friend told me he had one he never used and I bought it for about 1/4 new price. Sell some of your creations and buy one with the proceeds. Mine takes that finish off flooring REALLY fast. Many guys on here have built their own but I’m not that talented. You probably are!
-- " I'll try to be nicer, if you'll try to be smarter" gfadvm
JoeyG
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1161 posts in 797 days
#9 posted 503 days ago
I would love a drum sander. I am not sure I have room for it. I will have to post pics of my shop soon. It’s a one car garage. Long and narrow. I may have to make space at some point in the future. As far as making one, I am not that mechanically inclined. I wouldn’t even know where to start. LOL
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks
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