|Project by LoydMoore||posted 09-10-2013 01:14 AM||1211 views||3 times favorited||7 comments|
Lot’s of design options using this technique. Once the templates are made it only takes about 1 hr of actual work to build the board from start to finish. Since I was doing some heavy router work on the second face, I allowed the first glue up to set in the clamps overnight.
The wave templates are made from 1/2” MDF. I separated the two sides with a 1/4” bit and then faced them with 1/8” maple strips. Just used the same glue up procedure I use to glue up the ribbon style boards. As an added precaution I waxed the working faces of the maple strips before glue up. IMO, facing the edges made for a much better fit since any dips or bumps in the MDF were leveled out.
It is important to match the template sides together and mark a “0” point on both boards. Then just make sure the “0” point is aligned with one end of the board. I used blue tape so that I could move the design around on the template.
Attach the template to the hardwood of your choice with DBL back tape and band saw as close to the template as possible without damaging the template. Just run the template edge along the lower bearing on a real good trim bit (I don’t think I would try this with a $20 bit). I found that there is a real tendency for tear out when going into the tangent of outside radiuses so I did a climb on that area.
Caution: a climb cut on a router table against 1 1/4” hardwood is dangerous. A clean floor, good stance and patience ar necessary.
-- Loyd, San Angelo, TX http:www.moorewoodenboxes.com