I wanted to make a curved lid for my “Ute Box” so I spent most of the day perfecting a “Curved Vice/Clamp” jig to do the job,
Backgound: The staved part of the lid has five sections joined by a loose tongue and groove at a joint angle of 10 degrees.
Some years ago I made some stave projects and had a steep learning curve trying to glue them all together, in that case I used a plastic cable drum and ratchet straps.
This time I wanted to use a curved vice or clamp so I set to work with some sophisticated plans drawn in chalk on the garage floor.
I made a prototype with some small identical stave pieces to get a concept of what I needed, they are the items sitting at the front.
The frame held the center stave at zero degrees the the next two were at 10 degrees then 20 degrees at the final pieces
There are three frames duplicated with exactly the same dimensions to hold the lid staves in this case.
I used my drop saw at 10, and 20 deg and cut each block on either end of the timber then moved to the table saw set at 90 deg and a stop block set at the required heights.
I cut up the blocks to the required lengths from the measurenents taken directly from the physical setup.
I used a slot cutter set up in my shaper and a temporary 5 deg table to achieve the T&G alignment
The odd looking staggered ends are for a end piece which will be cut into the top after the glue has set.
Have a look at the small lid to the right I made some years ago this may explain the concept of the odd looking ends.
It all fitted together well and I was pleased with it. Issy Swan would be proud of me!!
Tomorrow it will be tested when I do the glue up, possibly all a bit over the top for a box (no pun intended) but it was enjoyable getting the jig perfected
-- Regards Robert