A journey into the workshop. #30: More progress on the extension wing.

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Blog entry by dbhost posted 12-19-2009 01:56 AM 1273 reads 0 times favorited 1 comment Add to Favorites Watch
« Part 29: Making progress on the extension wing. Part 30 of A journey into the workshop. series Part 31: Router got away from me. Start over, or patch? »

Well, I went to the BORG today, and picked up the tempered hardboard. I had them cut it a hair large, which was a good thing. My plan was to laminate it up, then use a flush trimming bit to even it up. Well it would appear that the panel saw at the League City Home Depot doesn’t cut quite square. From top to bottom of the cut I had him make (split the sheet right down the middle at 48”, the top to bottom variation was over 1/4”. I know, these are rough cuts, and thankfully I told the kid 48.5” and the material is 8’1” so I am good…)

So I got it home, made sure it was enough to overlap the base, and dug out the glue bottle / roller. A generous amount of Titebond II was applied, the hardboard was applied over top, and then 2×4 cauls were put in place and clamped down.

While the glue is drying. I set up the router with my flush trimming bit so that I am riding the bearing just below the thickness of the hardboard…

Now we wait for the glue to dry, and THEN we trim it, and move on to the other routing tasks at hand.

Hopefully I can get some shop time tomorrow to flush trim this, and at least cut the slot for the miter track…

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1 comment so far

View Jim Bertelson's profile

Jim Bertelson

4179 posts in 3187 days

#1 posted 12-19-2009 05:52 PM

I hear you on the materials and the cuts. I got a 4×4 sheet of 1/2” birch ply a while back and I thought I would use it for the Soooper Sled base. There is a bunch of big chip-out where they cut the 4×8 foot sheet in half, and it has a little warp. I don’t think I can get any good 1/2” ply here. So I have a message into Timbo who used MDF on his, and I happen to have a bunch of 1/2” MDF. Or I can use some 3/4” ply, but that will make the sled that much heavier. Really don’t want to do that. My TS cuts through ply without any chipout at all now.

-- Jim, Anchorage Alaska

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