LumberJocks

CUTTING THE PYRAMID PATTERN

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Blog entry by kiefer posted 03-26-2015 03:36 PM 3577 reads 39 times favorited 32 comments Add to Favorites Watch

Finally got some pictures taken of the cutting process so here is the promised blog .

This is the is the cutter I use ( CMT box joint cutter set )


This is the sliding jig riding on the fence cheek ,glued and screwed together and nice and square to the fence with no play which is very imported.

The cutter installed and tilted to 45 DEG. and a insert just for this cutting operation.

Notice the pencil mark on the insert which indicates the setting of the fence for the first cut.




The indexing device I made consisting of some used lumber and two sections of cog belt ( used timing belt ) glued to the lumber with CA glue .
The section on the right is clamed to the fence rail with two C clamps and the left section is loose .
To set the distance I move the loose section on notch to the right and press it down and slide the fence against the end and lock the fence this is repeated for every cut .






I tape the work piece to the jig with masking tape pulling it tight against the jig and rubbing the tape down good .
The cutting height is important and is set to cut the groove but leave the surface intact between grooves ( a very small flat ) this is to ensure the board face is in touch with the saw table over its whole length .
I added a small cleat to the jig for the heel of the push stick to engage to and it allows me to use both hands to slide the jig through the cut and also hold the panel down to the saw table .


Now the cutting the other way with the index device reset and using the push stick .




Here is the results and they turned out very precise as you can see with the two boards clamped together which are reversed end for end and engage perfectly indicating that the indexing device is working with good precision as simple as it is and you can also see the small flats I left on the top of the pyramids.
A close up as good as my camera will take .
The board have to be nice and flat and have no twist or imperfect result will happen .
I hope this explains it well enough but if there are questions please ask .
Now its on with finish building the box for my buddy and it will be the same look as the 1882 box I posted previously if you care to look at my projects .

The pattern on last box I posted is made the same way with the difference being that I laminated three pieces with a walnut as a core and two outside layers of maple about 1/8” thick .

http://lumberjocks.com/projects/138426
Klaus

-- Kiefer https://www.youtube.com/user/woodkiefer1/videos



32 comments so far

View SPalm's profile

SPalm

5257 posts in 3349 days


#1 posted 03-26-2015 04:02 PM

Neat. Good blog. Good techniques and jigs in there.

Love the timing belt indexer.
I guess this could be done on the router table with a cove or bit too.

Thanks,
Steve

-- -- I'm no rocket surgeon

View DocSavage45's profile

DocSavage45

7708 posts in 2309 days


#2 posted 03-26-2015 04:59 PM

Klaus,

The jig impresses me as much as the pieces it produces. I am working on jigs and they are simple by the Kiefer comparison. I’ll need 20 years to catch up. I know it’s your experience and familiarity, but it’s also your artistry with your tools.

Thanks for posting this for us mere mortals. LOL!

It looks like you even customized your Shop Fox fence?

-- Cau Haus Designs, Thomas J. Tieffenbacher

View shipwright's profile

shipwright

7175 posts in 2264 days


#3 posted 03-26-2015 05:42 PM

+1 on the timing belt indexer.
I think you may have more uses for these things than the automotive industry does. ...... and without all the pollutio

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

View Paul's profile

Paul

444 posts in 3056 days


#4 posted 03-26-2015 05:43 PM

Excellent, thanks.
Paul

View Tomoose's profile

Tomoose

410 posts in 2840 days


#5 posted 03-26-2015 06:11 PM

This is simply brilliant. Thank you for the fine explanation; the photos really help. Keep up the fine work – I try to look at all of your posts and they never disappoint!

Best,
Tom

-- “I am always doing that which I cannot do, in order that I may learn how to do it.” Pablo Picasso

View madts's profile

madts

1685 posts in 1806 days


#6 posted 03-26-2015 06:25 PM

Very smart idea, using the cog-belt that way.
Thanks for that great project.
At least it inspires me.

-- Thor and Odin are still the greatest of Gods.

View kiefer's profile

kiefer

4881 posts in 2134 days


#7 posted 03-26-2015 06:54 PM

Thanks for taking a look guys and I hope you enjoyed it .

SPalm/Steve
I don’t think a router bit would do as good a job and would get dull way before a blade will and also would cause some burning and tear out that is why I use the table saw for this .
Also as a side note :
The index spacing can be varied by adding a removable shim at the contact point of the fence and the index bar,
the cog spacing on this belt is 8mm but adding a 4mm shim it can be reduced to 4mm and so on by alternating with and without shim .

Klaus

-- Kiefer https://www.youtube.com/user/woodkiefer1/videos

View doubleDD's profile (online now)

doubleDD

5247 posts in 1510 days


#8 posted 03-26-2015 07:10 PM

A genius of an idea and yet you made it so simple. I was wondering what you used to make the measurements so precise. Timing belts, excellent and perfect. The box cutter also surprised me. I hope to use this sometime in the future. Thanks for giving us this Klaus. Now get to work.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Stoli's profile

Stoli

57 posts in 2834 days


#9 posted 03-26-2015 07:10 PM

Cool—You made your own Incra Jig!

View SPalm's profile

SPalm

5257 posts in 3349 days


#10 posted 03-26-2015 07:36 PM

Hey Klaus, not to steal your thread, but I remembered this box from somebody on Etsy:

I guess they used a core or round nose bit.
Steve

-- -- I'm no rocket surgeon

View kiefer's profile

kiefer

4881 posts in 2134 days


#11 posted 03-26-2015 08:13 PM

Thanks Steve
That looks cool I like it this would make a nice ring presentation box .

Klaus

-- Kiefer https://www.youtube.com/user/woodkiefer1/videos

View JL7's profile

JL7

8427 posts in 2432 days


#12 posted 03-26-2015 10:06 PM

Thanks for the detailed write up Klaus, good stuff! I’m now on the lookout for old timing belts!

-- Jeff .... Minnesota, USA

View JL7's profile

JL7

8427 posts in 2432 days


#13 posted 03-26-2015 10:08 PM

And Steve – thanks for the cove bit ideas! Probably won’t sleep tonight…....

-- Jeff .... Minnesota, USA

View gfadvm's profile

gfadvm

14940 posts in 2157 days


#14 posted 03-27-2015 12:02 AM

Great blog! I would never have thought of using a timing belt! Added to my many favorites to be done when I’m caught up on all my other “stuff”.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View jaykaypur's profile

jaykaypur

4006 posts in 1875 days


#15 posted 03-27-2015 12:36 AM

Nice blog and a great jig….....now if I can just find me some of those timing belts!

-- Use it up, Wear it out --------------- Make it do, Or do without!

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