Newest Baltic Birch Ply Scroll Saw Shell

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Project by alwaysscrolling posted 03-12-2016 11:27 PM 2797 views 6 times favorited 13 comments Add to Favorites Watch

Made another Scroll Saw Shell out of Baltic Birch Ply. I used 6 wedges on this one which resulted in 72 segments. The overall length of the Shell opened and before the gluing stage is over 43”. The mouth opening measures 9.5” wide and it is 8” deep by 9” high. The finish is approximately 8 coats of spray poly. The stand is made from the left over pieces of the wedges of the shell parts. They are a lot of fun to make. Thanks for looking. Ron

13 comments so far

View toyguy's profile


1593 posts in 3651 days

#1 posted 03-13-2016 12:37 AM

I just love these things. One day I am just going to have to give one a try.

-- Brian, Ontario Canada,

View Bob Collins's profile (online now)

Bob Collins

2456 posts in 3497 days

#2 posted 03-13-2016 01:09 AM

Very nice, like the use of plywood on these shells. Great finish.

-- Bob C, Australia. Your best teacher is your last mistake.

View bobasaurus's profile


3340 posts in 2997 days

#3 posted 03-13-2016 02:12 AM

That seems like a ton of work. No idea how you make all that on a scrollsaw.

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

View htl's profile


3058 posts in 973 days

#4 posted 03-13-2016 02:25 AM

These are just so cool!
Would love to make one some day.
You’ve made enough of them now, you’ve got it down pat.

-- There's a hundred ways to do anything, alot depends on the tools at hand.

View pottz's profile


2116 posts in 798 days

#5 posted 03-13-2016 02:33 AM

ron you rock man that is just plain cool dude.welcome to lumber jocks and I cant wait too see more of what you do.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View oldnovice's profile


6391 posts in 3181 days

#6 posted 03-13-2016 02:47 AM

That is one beautiful she’ll … the finish is just outstanding.
I really like the direct frontal view.

-- "I never met a board I didn't like!"

View Chad's profile


15 posts in 624 days

#7 posted 03-13-2016 12:30 PM

Wow! I have no idea how you did that on a scroll saw! Amazing work!

View greyspider's profile


90 posts in 2737 days

#8 posted 03-13-2016 12:41 PM

I love these shells. I just acquired a DeWalt scrollsaw and would like to make one of these. Could you please point me in the right direction? Thanks


View alwaysscrolling's profile


20 posts in 655 days

#9 posted 03-13-2016 05:44 PM

Many thanks for all the great comments. Again these are a lot of fun to make and the cutting process is not as difficult as you may think. I believe the cutting process of all parts to make the shell is somewhere in the ballpark of less than 6 hours. That’s the easy part. The gluing, shaping and sanding stage is where the real time takes. Overall I have approximately 30 hours in this Shell.

For those interested in learning more, Steve Garrison has an e-book available which will provide more detail than you can imagine. If you look at facebook and search for Scroll Saw Shells you will find a dedicated section to these Shells. There you can also find details on info on his e-book. You can also go to Youtube and search Scroll Saw Shells and find video instructions on how to make them. Someday I hope to make a video and post it there as well. Always willing to share info as needed. Thanks again, Ron

View helluvawreck's profile (online now)


28755 posts in 2680 days

#10 posted 03-13-2016 07:17 PM

This is a real beauty. Congratulations.

helluvawreck aka Charles

-- If a man does not keep pace with his companions, perhaps it is because he hears a different drummer. Let him step to the music which he hears, however measured or far away. Henry David Thoreau

View Diggerjacks's profile


2208 posts in 2952 days

#11 posted 03-14-2016 07:25 PM

Hello Ron

Another fantastic scroll sawing work
I like it very very very nice

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Tsharp's profile


16 posts in 681 days

#12 posted 03-20-2016 11:25 AM

Ron, this shell is on my top 3 favorite LJ projects I’ve seen yet! The Baltic birch really gives it a unique touch

-- Todd Sharp

View alwaysscrolling's profile


20 posts in 655 days

#13 posted 03-20-2016 05:49 PM

Many thanks again for all the great comments. I am presently working on another Baltic Birch Ply Scroll Saw Shell. This one will be about 1/3 larger than the one posted. Just wanted to see the results of going larger. Will have it posted soon. About 90% complete. As mentioned, these are a lot of fun to make. Ron

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