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Woven Wood Doors, Part III Recovery4/5
Part Three - Recovery
We needed to come up with a Plan B for shaping the curved face parts. We did not have one, though my original plan was a linear jig, with the appropriate curve along an edge. Or maybe two. The circular jig won out since we thought it adequate, and cool.
So, Justin started in on a straight jig. We would go back to hand feeding since I felt we needed that feedback. We turn the feeder around and attach a ‘foot’ to the horizontal beam and use it as a hold down, guard and general security. We used a fixed bearing under the cutterhead since we could easily adjust it for flush on our parts.
The big change was to cut half the face of each block, from the center, on the downhill run, not into the grain. This meant each block would have to be set, run and removed 4 times, 500 passes. The jig would hold three parts, so it needed to be loaded 166 times to run the parts. This is what I /we wanted to avoid. You can’t always get what you want…..
The jig is similar to the circular Jig of Doom, but unrolled. The blocks fit onto a lower horizontal tongue and two vertical tongues, a wedge is driven to tighten the verticals, and a one piece top tongue was fit into place. Handles were added for control, and it was ready to test. The base that the handles mount to also has the curve x 3 along the edge facing the cutter. The jig had mass, accuracy and a snug hold down that held the blocks tightly.
At times, it is like you pay your dues one place, and are rewarded in another. The parts came out close to perfect, no scary stuff or minor explosions. Even the center matchline came out almost unnoticeable. Sanding would be easy. It made no difference what the grain direction was, coming off the high part to the thinner worked just fine. We did not loose a single part.
I continued making blocks and getting them ready for the shaper. Justin spent a day to do the double duty on the shaper, but never complained. The stiles and rails were ready, as simple as they were, but we wanted to wait to size everything until we made up our panels.
With blocks shaped, we could finally see the pattern come up before our eyes as we placed the parts on the bench. It did look woven. Lots of depth to show the shapes, and the shadows said the rest. Very unusual. I have never seen anything quite like it.
You've got pocket screws, screws, glue various kinds of clamps, including two decorative hand screws. Where is the duct tape & cable ties?
What is the story regarding the knives being longer than the cutterhead? Is this really advisable, and if so what is the limit?
Well, yes. The knives extended above and below the corrugated head. I agree there is a limit as to how safe that is, but we were not near it. The knife stock was 5/16” thick, and at no point did they have to cut anything deeper than 3/8”. I used to make 2-1/2” wide panel raises in Oak with 5/16”serrated edge beveled edge knives in a bearing head at 6,000 rpm - almost daily. You may not like to do that, but it works.
I will say I do not advise it, but I felt there was no risk. The biggest threat was from reaching over the spindle. A better guard would be practical and easy if this were to be done more than a few hours in one day.
Justin has been working with me for 5 years. He is a wonderful hand in all respects, but at times of stress he resorts to his previous carpenter ways. Especially pocket screws. He felt badly that the circular jig did not work, especially since it had a good measure of elegance. The next jig was dead functional, pocket screws and all. Neither jig came loose or needed to shored up during or after running the parts. Duct tape would probably suffice....
I don't know what are decorative hand screws. The ones in the last photo are holding a hold down foot to keep the jig in line, and press the top and upper spline in place.
I will admit that at times we are not as elegant as we like. The duct tape and cable ties were not far away. We think of what the jig must do as one thing here, one thing there. So it is pieced together. Once it is proven, we can then see where we could economize on parts and let some perform two functions. These more evolved jigs would be used more often, and add to the job satisfaction. Our louver groover is an example of a third generation jig that does it all and is elegant in function. Same with the dovetail jig.
I retract part of my previous statement. The handscrews are obviously not decorative. They are one of the most underutilized clamps. You just don't see them used in such a manner hanging out there for everyone to see.
We've used plenty of hotglue and double back sticky tape to make all kinds of jigs and rigs. The duck tape is always a concern. It works so well it might be permanent. As for cable ties...they are permenant.
Thanks Dave for posting this warts and all
Would you be interested in making something with a european copper beach? Very rare check out these pictures. Its 400 years old.