I am probably going to keep today’s post short. I know every time I say that, I wind up rambling on and it doesn’t turn out to be that short at all, but today I really think that will be the case.
I had another good day working yesterday. I did finish cutting out all the pieces for the kits and everything went according to plan.
Now for the drilling . . .
In thinking about how to do this, there were several think I needed to take into account. While some say it would have been easier to drill the pieces out before cutting them out, I have to disagree. R
Remember I had everything on 10” square sheets of plywood stacked 4 pieces high? This made for thicker pieces that would have been a bit clumsy to maneuver on my small drill press. The distance from the back of the throat of the press and the bit is only 4” too, which meant that there was a 2” square section in the center of the boards that would not be accessible by the drill. In order to make sure that nothing in that central area would need to be drilled, I would have to be sure to lay out the pieces in such a manner that it would be so. I already had layouts so that I used the wood in the most efficient way, and adding this factor in would not make it possible for me to cut without costing me much more in wood. So that was out.
Another factor is that I am using a very small bit for these entry holes. Lining things up quickly and going through four layers of plywood with a small bit to drill quickly and efficiently would in all likelihood for me cause me to break bits. I just don’t think I would be able to do it as quickly as necessary without doing so.
Finally, since the four layers are only tacked with hot glue at the four corners, drilling in the middle would result in a slight amount of tear out in between the layers. I wanted to avoid that if I possibly could.
So cut first and drill afterword was the best option.
In order to close the hole and make a ‘zero clearance’ table on my drill press, I simply used double sided tape on the back of a small square of plywood and stuck it onto the table. I was ready to go.
Working like this supported the pieces beautifully and I had no problem whatsoever with tear out.
As far as lining the pieces up, that wasn’t much of a problem either. I started with the hats, in which there are four different kinds. While it was suggested that I use a jig, I think that building one for each of these four pieces would have taken me more time than the actual drilling. There are also four boots as well as eight different pumpkins so that would mean in total that I would need to make 16 different jigs.
I decided to just ‘go for it’ and started drilling away. I got through the pile of 1200 hats in a matter of about an hour and a half. It really went quite quickly and I didn’t see it being much of an issue. I had some nice lively music playing in my headphones and I had chosen to take the drill press out on the deck, as it was a beautiful warm day and the sun was shining nicely.
I quit after the first batch because I needed to get to the store and find some boxes that I will be able to ship these in. I want to be able to just pack them and stack them into the boxes all at one time. That way the pieces won’t shift and I will be able to have each kit in a flat layer for shipping most efficiently.
I need to finish drilling the other two sets today, and I expect that to take about 2-3 hours to do so. The rest of the day will be spent packing the kits and boxing them up, as we are now in the home stretch.
I am excited about seeing these kits come together. Again I say that doing the work really wasn’t that bad. I feel that it helps build my accuracy skills on the scroll saw and it did give me a lot of time to think about the other new things that I will be creating in the near future. My idea book is really filling up so I have lots of new things on the horizon. Taking on this job gave me a good chance to take a breath and get my ideas lined up, as well as gave me the opportunity to do something that I like to do.
I hope you all have a wonderful weekend. It looks like it will be another nice day again here today and I look forward to making a great deal of progress with getting these ready to ship.
Have a good one everyone!
-- Designer/Artist/Teacher. Owner of Sheila Landry Designs (http://www.sheilalandrydesigns.com) Scroll saw, wood working and painting patterns and surfaces. "Knowledge is Power"