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Making Mouldings #1: Boat bench Moulding

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Blog entry by robscastle posted 02-21-2013 03:46 AM 1419 reads 0 times favorited 2 comments Add to Favorites Watch
no previous part Part 1 of Making Mouldings series Part 2: The mouldings fitted up. »

I had a call from a customer who was restoring a boat.
They wanted me to make some scotia moulding for a galley bench, my imediate thought was just go and buy it.
Anyway the conversation continued on and the dimensions were 140mm x 32mm Tasmanian Oak.
Thats certanily bit on the big side and I didnt think you could even buy plaster types that were that big.

As they had the material already and I was becoming confused as to just exactly what they wanted I asked if they could drop by to discuss so I could fully understand the requirements. It was agreed and in 1.5 hr they would arrive, in the mean time on some graph paper I plotted out some scotia with the dimensions given then scatched my head for a method to produce such a large item.

I knew I could do it on my table saw so decided I would go that way, finished the drawings and waited.
The customer arrived timber in hand and we talked.
It turned out what they really wanted was a splashback with a radius on the splashback to match the bench.

I accepted the job and took delivery of the timber and asked for a test sample to “experiment” on.
They had no problems in providing it as they said there was no were else that would do the work for them.
As it turns out what they really wanted was:-

I spent quite a bit of time perfecting a method of producing the profile, or so I thought.
My initial plan was to saw out a rectangular section an then run the router along it with a cove bit then use the shaper it to produce the final finish. (See the photo of the test piece)
Too easy !!

After experimenting with the process I decided to do it on the router and shaper first finishing with the table saw.
Meaning route the cove section and then mill the material away in the shaper.

The main reason for doing it this way was because my CT-22CS shaper/moulder has only 36mm of rise.
Meaning with the cove section at 25.4 and offset of 29mm I still had 112 mm or there abouts of material to remove.
So using a 50mm straight cutting shaper bit I could do the job.
What concerned me was the final cut with no datum to guide the timber may produce a less than acceptable result, so to overcome this I left a small section on at the end and cut it off with the table saw later.

There were about five destinct steps in the process, not accounting for incremental depth cuts.

Step 1
Cut a 25.4mm diameter with a cove bit using the router, this took a few passes as well.

The photograph shows the test piece I used to check everything was OK as I progressed.
You can see the original Table saw idea on the left, the section of “loose material”

Steps 2, 3 and 4.

Using the shaper remove almost all of the material above the cove this was done in several passes.

Step 5
Remove the remaining material on the table saw
I dont have a picture of this but its simply set up the fence and remove the material shown in the diagram/ picture of the steps.

What sort of a result did I achieve?
Well check for yourself,.....construcive comments are welcome here!!

Now shown assembled with the remaining off cuts

Just goes to show, 2D plans are OK but when it comes time to making the final product human instinct kick in regarding what you are personally happy to deliver the customer with.
It was an interesting small job.

Tools Used:- 1/2 ” Router, 1/2” 25.4 cove bit, CT-22CS Shaper/Moulder and a 50mm and 25mm straight cutter 10” table saw.

Material Supplied:- Tasmanian Oak 135mm x 32mm x 2m
Time involved:- Initial setup and planning about 1 hr. Setup and route the cove 15m. Setup and then to mill the profile 30m. Cut and square timber cut a 45 deg on both ends 15m (To be done upon return of customer) (total time 2h)

Enjoy

Regards
Robert Brennan

-- Regards Robert



2 comments so far

View ksSlim's profile

ksSlim

984 posts in 1547 days


#1 posted 02-21-2013 06:43 AM

Everyone picks their own path,
The destination is only an objective that requires over coming obstacles.
Looks like you’ve arrived.

Adapt, improvise, overcome.

Move on to the next.

-- Sawdust and shavings are therapeutic

View Robb's profile

Robb

660 posts in 2591 days


#2 posted 02-22-2013 10:03 AM

Nice concise explanation of your thought process to break down the problem into manageable steps. Did the customer like the end result?

Thanks for sharing!

-- Robb

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