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Forum topic by PantsBoy posted 01-05-2015 05:26 PM 1674 views 0 times favorited 11 replies Add to Favorites Watch
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PantsBoy

16 posts in 754 days


01-05-2015 05:26 PM

Topic tags/keywords: question

Hi all,

I’m fairly proficient in woodworking but have never really carved anything since school days (quite some time ago). A customer asked me to give an estimate for making the following piece:

Apart from making it in two pieces (a thinner piece, cut with either a jigsaw or scrollsaw laminated on top of a thicker base) what other options are there? I do small production runs of kitchenware (boards and utensils etc) and some limited custom work. Looking to expand the custom work a bit and this would be a nice ‘fancy’ one to showcase.

Thanks!


11 replies so far

View dawsonbob's profile

dawsonbob

1912 posts in 1217 days


#1 posted 01-05-2015 05:32 PM

Do you have a router?

-- Mistakes are what pave the road to perfection

View ChrisK's profile

ChrisK

1809 posts in 2543 days


#2 posted 01-05-2015 05:46 PM

A router with a few templates looks like the way to go.

-- Chris K

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PantsBoy

16 posts in 754 days


#3 posted 01-06-2015 07:12 AM

I do have a few routers (like clamps, you can never really have too many)

So, routing it and then smoothing the bottom with sandpaper? Sounds like it could work … I’d make a MDF template, or a few smaller ones for the different shaped holes?

Thanks for the replies!

View Dan Krager's profile

Dan Krager

3256 posts in 1696 days


#4 posted 02-20-2015 11:43 PM

Late to the party, but templates applied to the flat plank before glue up, allowances made for joinery, is how I would proceed. Touch up after assembly.
DanK

-- Dan Krager, Olney IL http://www.kragerwoodworking.weebly.com There are three types of people...those who are good at math and those who aren't.

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PantsBoy

16 posts in 754 days


#5 posted 05-11-2015 12:33 PM

Finally started getting my shit together.

Complete template stuck to the raw bench with carpet tape:

Some detail of the side / leg template:

And carved with a router with straight bit and guide bushing. I also screwed a much larger piece of hardboard to the base plate of the router to keep it flat over the larger holes – it worked a treat.

Now for some sanding, and then finish!

View shipwright's profile

shipwright

7167 posts in 2260 days


#6 posted 05-11-2015 01:21 PM

Looks fine.
Late to the party but I think I would have sliced the inset thickness off the pieces before glue up and cut them as your original thought with a scroll saw. They could be replaced exactly matching the grain underneath but after the base was sanded leaving nice sharp clean corners. If assembled with hide glue there would be no finish blocking problems.
I don’t envy you the sanding task you have ahead of you. ......... but as I said,.. looks fine.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

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PantsBoy

16 posts in 754 days


#7 posted 05-12-2015 12:04 PM

Hi Shipwright – and how would you ‘slice’ that section off?

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shipwright

7167 posts in 2260 days


#8 posted 05-12-2015 01:50 PM

Resaw on the bandsaw. If it is for example 1 1/2” thick, I’d resaw it into (nominal) 1 1/4 and 1/4 or 1 3/8 and 1/8.
Then you could flat sand the thick piece and glue the thin piece back in exactly it’s old position after cutting it out.
Your way certainly worked, just maybe harder to sand. The glue type would be critical though as pva could block finish and would be hard to repair.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees. http://thecanadianschooloffrenchmarquetry.com/

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PantsBoy

16 posts in 754 days


#9 posted 05-22-2015 11:36 AM

A clearer pic of the bench. Going to try and take some nice pics over the weekend, client’s overseas at the moment.

View jim65's profile

jim65

808 posts in 1395 days


#10 posted 06-23-2016 08:22 PM

Really late to the party, but I think it turned out fine! best with the router, you don’t actually want really sharp edges on a bench. final pic is very nice.

-- Jim, Marostica Italy

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PantsBoy

16 posts in 754 days


#11 posted 06-24-2016 08:41 AM

Thanks, Jim. I’ve been using that template to make children’s toy chests as well – but here I’ve cheated and painted the holes instead of sanding them :D

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