Baltic Birch Ply Scroll Saw Shell

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Project by alwaysscrolling posted 02-13-2016 11:55 PM 4166 views 11 times favorited 11 comments Add to Favorites Watch

This is my latest Scroll Saw Shell. It is made out of 1/2” Baltic Birch Ply. With this Shell I wanted to experiment with larger pieces to see the results in the size of the Shell. I started with the Ply cut to 6” x 10”. I glued 4 of these pieces together to make an overall thickness of 1 7/8” and I made 3 of these stacked glued pieces. Once the edges were trimmed square, I cut the angle for the 6 wedges on the band saw. For this Shell I used 5 wedges which resulted in 61 segments. I decided to include a photo of the 61 cut segments. From there you start gluing segments together and shaping and sanding prior to additional gluing. One of the photos also shows all 61 segments glued together into a final 4 sub sections prior to final assembly.

The overall dimensions of this Shell is approx. 9.5” wide by 9.5” tall. I used the 6th wedge to make a stand for the Shell. The finish is a few coats of Tung Oil.

Thanks for looking.

11 comments so far

View BobWemm's profile


2593 posts in 2168 days

#1 posted 02-14-2016 01:31 AM

Just beautiful.
One of these is on my list for one day.
Thank you for sharing.


-- Bob, Western Australia, The Sun came up this morning, what a great start to the day. Now it's up to me to make it even better. I've cut this piece of wood 4 times and it's still too damn short.

View pottzgt's profile


34 posts in 1102 days

#2 posted 02-14-2016 01:37 AM

These things really are awesome, I’m glad you showed the break down of the shell, its a good perspective of what goes into them. How long does it usually take you to make a shell?

-- Terry, Grants Pass, OR - It's not how fast you want to go but how much money you've got to get there...

View htl's profile


4329 posts in 1401 days

#3 posted 02-14-2016 01:38 AM

Just beautiful an out standing project.

-- An Index Of My Model making Blogs

View rustynails's profile


812 posts in 2771 days

#4 posted 02-14-2016 02:27 AM

Great job … love the shells

View Bob's profile


11 posts in 1077 days

#5 posted 02-14-2016 03:08 AM

Wow – Outstanding job on this one – Someday maybe on my to do list as well – Very Nice

-- Bob,Colorado

View Pointer's profile


440 posts in 1353 days

#6 posted 02-14-2016 04:08 AM

This is way cool.

-- Joe - - There is no elevator to success. You must take the stairs.

View BurlyBob's profile


6034 posts in 2507 days

#7 posted 02-14-2016 04:52 AM

That is an incredible piece of workmanship.

View dozuki's profile


103 posts in 3242 days

#8 posted 02-14-2016 05:54 AM

Well that looked so awesome that I had to try it and man getting those wedges right isn’t easy. My hat is off to you. This one looks awesome as well.

-- Couldn't think of anything clever. I LIKE WOOD

View helluvawreck's profile


32086 posts in 3108 days

#9 posted 02-14-2016 01:51 PM

This piece is beautifully done.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View DonSol's profile


249 posts in 1483 days

#10 posted 02-14-2016 05:15 PM

I’m not sure how you do it but they are beautiful. Thanks you for sharing this.

-- Don Solomon, New Castle, IN; Quality is not an act, it is a habit. Aristotle

View alwaysscrolling's profile


20 posts in 1083 days

#11 posted 02-14-2016 06:07 PM

Many thanks for all the great comments. I am no doubt very excited about my project being placed in the Top 3 Daily projects. These are a lot of fun to make and the process is not as difficult as it may appear. I am presently working on another Baltic Birch Ply Shell and have been logging my time in the various stages. Overall these large Scroll Saw Shells take between 25 & 30 hours to complete with the cutting, gluing, shaping, sanding and finish. I do like the look of the Baltic Birch Ply due to the more realistic look of the Shell with the lines and colors.

Again thanks for the looks and comments. Ron

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