|Forum topic by richgreer||posted 06-17-2011 09:17 PM||1222 views||1 time favorited||8 replies|
06-17-2011 09:17 PM
If you have seen my recent posts you know that I am completing a large project in which we made 72 pew end panels for the pews at my church. This has been a very educational experience for me.
I made several mistakes and, in theory, I learned from those mistakes.
Here is something I discovered that many of you probably already know.
After glue up, we drew an outline of the desired shape using a template. We then did a rough cut where we cut close to the line with a combination of a plunge saw with a track for the straight cuts and a jig saw for the curves. We then attached a template and used a straight router bit with a guide bearing on the end to do the final shaping.
I’ve used this technique many times with no problems. I always grabbed some scrap sheet material (plywood, MDF, OSB, . . . ) to make the templates. Of course, I was always using the template for just a few cutouts (not 72). This time I used some OSB I had laying round to make the templates.
Discovery – - The edges of the OSB will breakdown and get rough when used as a template many times. This results in a rough cutout and the need for a lot more sanding. In this application I think MDF (or even particle board) would work better. In my case, I discovered that a previously cutout pew panel that had to be discarded because of a major mistake on the cross inlay was a great template.
FYI – I decided to attach the template for routing to the stock with 2 little wood screws. I did not want to mess around with double sided tape. The 2 screw holes will be hidden on the inside of the pew panel at the seat height.
-- Rich, Cedar Rapids, IA - I'm a woodworker. I don't create beauty, I reveal it.