|Project by ilyac||posted 03-29-2015 08:30 PM||1038 views||1 time favorited||1 comment|
Yet another shop project that I only learned I needed after my first cutting board project, and some amount of screaming to the heavens “There must be a way to get even clamping pressure all along this damn thing!” (and then Googling, obviously)
Enter: The Cauls
I made these from 2×4’s I picked up at Home Depot. I made the curve by clamping my ‘slightly weathered’ straight edge (i.e. the one i don’t mind too much if I use for such tasks) to the edge of my workbench and placed a pencil at the midway point and used my router to make the edge on a piece of 1/4 MDF. I screwed that down to my table, and routed the profile on the 2×4’s with that. It’s hard to hard to seen in the photos, but I screwed the 2×4 piece under the MDF.
The final size was 1-1/2” at the thickest point, 24” long, and 1” wide. From center to end I have about a 3/16” drop. I would have preferred it be wider than 1”, but with my router bit and this set up that the widest I can edge without having to flip the piece over, switch the router bit (and collet) to then use my bit with a bearing.
It’s not as perfectly matched as I would have liked, but hopefully I can either sand that out, or just fix up my template.
1. My first attempt I put too steep a curve on my template. I could not even get them to close before my clamps flew off the ends.
2. I may need to ease off the router, or take more progressive passes, at the ends as i did mess one piece up because the soft 2×4 blew out.
3. Using a 1/2” piece of MDF may have been a better idea for the template, with the way I have it set up now it tends to move just slight as I apply pressure. Not sure if that is what caused my edges not to line up just right, but It could not hurt.
4. I first tried to cut the curved template with a jig saw, but that did not work out so well and I could not get a nice smooth curve when I tried to file down.