This is a simple project that is made more so with a couple of templates. In fact I would not know how to line things up accurately without them. I use two kinds of templates, one to line up drilling and a couple to space the wings. For pictures and previous discussion check out my project page and blog series.
I start by laying out the design on graph paper and tape that to 1/4” masonite cut to the same size as the inner top and bottom. I then sandwiched an identical size piece between it and the outer bottom template. Then center punched all the holes and drilled pilots through the sandwich. Here are some quick dimensions. The inner top and bottom are 3 3/4” x 9 1/2”. The outer top and bottom are 1” wider and longer creating a 1/2” border on all sides. The wings are 7/8” thick x 3 1/2” wide x 10 1/4” tall and are angled 15 degrees inward, about 1/2” from the back edge. The wings are spaced about 1 1/8” apart – more on that in Blog #2 of this series.
The Galileo thermometers run about 11” to 11 1/8” plus or minus due to vagaries of glass blowing. The Galileo hole is 1 1/2” and positioned 1/2” back from the front edge. The holes will be drilled through the inner top and 1/4” into the inner bottom. The six holes in V formation are for 5/16” dowels. Note, the hole on the right is also used for a pivot for the outer top. The two back holes are for 10mm x 5mm magnets which need to match to holes on the underside of the outer top. Whew, say that fast three times. Also check out my first blog to see how I screwed up the magnets.
At this point you do not need to drill the actual size holes. Just a small pilot hole. Since the masonite has both smooth and rough sides, it is easy to maintain orientation with the smooth side up. The V pattern is used to orient the front and back.
Here’s a shot of the three separate templates with the pilot holes. As you can see the bottom two are identical. Now Grasshopper, why do I need two identical templates you ask? Well you didn’t ask but here goes. In making the first two stations I made a little discovery that is obvious to most people, not so to me. It is this thing called gravity. I learned it is always better to let gravity work in your favor instead of fighting it. So how does this enter the picture? You’ll have to wait for Blog 2 in this series. I know, I know… the suspense is killing you. Stay tuned.
-- tim hill www.newcalshop.com