I saw this picture of the Ninja Turtles in Minions getup
My grandson who is four loves both.
So the head scratching begins, how could I make something safe and yet had the ability to be changed later when another favorite comes along.
I wanted to make a photo frame with no removable parts a child could get into so I decided on two halves pocket hole screwed together.
This is the final product assembled and waxed
I needed a routing frame the same size as the image, so dusting off all my templates I find a Carbitool 3d Router carver Handle surround frame which was almost the right size.
I cut a couple of “L” shaped inserts to reduce the internal size to what I wanted.
Fasten them around the New Guinea Rosewood timber I was going to use.
Then set up the router with a upcut spiral straight bit
Then did a test fit up to determine the bush I required
Satisfied all would work OK I routed out the first section, the front face section of the frame.
Once that was done it was now the undercut section, now as the back was still intact I could not use my conventional Rabbetting or slot cutting bits due to screws nuts and bearings on the bits touching the back.
I found this CMT Slat wall bit which I had never used and it looked like it had the profile I needed.
Again I did a test fit up and it looked like it would do the job.
With a bit of trial and error I found the correct bush as I didnt want the taper section of the cutter going any where near the face edge.
Stage two of the routing commences
All worked well, I had some scraps of perspex hence the “bullet Proof” piece!
Next it was time to section the material so I used the bandsaw to do the cut, mainly for low kerf.
then fabrication of the perspex window was completed. It was simply cut to size and then sand the corners round to match the internal profiles.
Clamp it all back together and add two pocket holes
Then final sanding and edge profiling followed by a coat of howards wax,
Hopwefully little fingers cannot get it apart
and thats a wrap!!
Well almost….. some terminology editing from Candy was required Minions not Millions… cannot do the photos so easy!! so they will have to stay, just hope Rocky does not see them or I will be in for it.
-- Regards Robert