|Project by Jerome||posted 05-15-2013 02:39 PM||2807 views||0 times favorited||4 comments|
Where do I begin? There were many trials and tribulations regarding dimensions and techniques that would be involved in this project. I will first start by saying that wood/material selection is important. The actual shield is cut from 3/4” pine plywood. The base is 3/4” sheathing that was used to make a crate, which I picked up near a stack of free pallets. The “frame” was made from a piece of 1/2” x 3” wood. I’m not sure what kind. The letter were cut from 1/2” pine plywood.
In the future I’ll spend a bit more and use Baltic Birch, or Birch as my primary material. Needless to say this was a semi-tedious ordeal, but I enjoyed testing my skills. It allowed me to get more comfortable with my table saw by making the strips of wood for the frame as well as squaring up panels i have in stock. The letters proved to be a good task to gauge the scroll saw performance. The actual shield was cut with my jigsaw, but the holes in the top of the handles and some of the tighter areas were cut with the scroll saw – thick wood blades.I will say the most challenging bit was getting the same depth for the circles without too much tearout. I used a spade bit, but Ill look at getting something else to achieve a flat circle at 1/4” depth. The tiny sword handle also broke off and I had to create my own “dowel” to make it strong again.
I realize a drill press could be useful, however, some areas are more than 8” from where I need a hole and I don’t foresee getting an 16” or larger drill press anytime soon. I do have a Skill router (not a plunge one) and I’ll probably see if i can create a template for the holes.
-- Jerome, Marietta, GA