|Project by OakHill||posted 09-29-2013 01:29 PM||3781 views||12 times favorited||6 comments|
Once the shape of the tea light holder was determined, a template was made for the profile and was also used to locate the candle pockets. The profile was roughed out on the band saw with a 3/16 wide blade leaving minimal stock for the profiling operation.
The next operation was routing the profile using the template and a 2’ long flush trim bit.
The fixture was designed to route ½ of the profile at a time. The blank with the template attached (with double sided tape) butts up against two short dowels. Because of the 1-1/2 inch thick blank it needed to be securely clamped.
Two “De-Sta-Co” (Model 227-U) low-profile hold down Toggle Clamps, with extra hand clearance and a 500 lb max holding capacity were incorporated. The ‘U’ shaped bar adds to the flexibility of adjustment of the hold down tip, in both the horizontal and vertical positions.
The De-Sta-Co brand was chosen because of my past experience with them designing fixtures in the machine shop environment. The quality and reliability has never been a problem. The rubber tips take up any minor variation in thickness of the blanks.
Two ½ inch diameter dowels were positioned on each side of the base to help guide the fixture through the profiling operation, keeping my hands safely away from the cutter.
The router bit used was an “Eagle-America” carbide tipped down shear flush trim bit. This style was chosen for its characteristics of eliminating chipped or splintered edges. It also is good for routing end or cross grains on hardwood and produces a smoother finish compared to straight flute cutters.
The next step was to remove the work piece with the template still attached to it with double sided tape and bore out the candle pockets with a 1-5/8 diameter carbide Forstner bit.
Tea Light Holder / Candle Centerpiece: http://lumberjocks.com/projects/89933
De-Sta-Co Clamp (Can be purchased from McMaster-Carr): http://www.mcmaster.com/#5091A13
-- John, Illinois, http://OakHillWoodCreations.com