Thank you! Figuring out the process the first time around was...challenging. My first brilliant idea was to use a carousel jig with a big straight knife head on the shaper. All it made for me was splinters as every piece I ran through grenaded on me. After I cleaned out my pants, it was back to the drawing board.
Thanks!
I jointed the stick straight, planed it for thickness and width, used a shaper to chamfer and the side dados. Sled jig with stop to cut to length, then sled jig with shaper for end dados. I built a carousel jig for tha bandsaw for the rough radius, then used a belt sander with a right angle table to smooth them out. I make extensive use of micrometers and digital readouts in my shop; very accurate sizing is the key to getting something like this together without gaps.
Wow, I knew it took some work, but that's quite the process. I'm also happy to see I'm not the only person to use a shaper in my shop. I've heard the argument that they only make sense when you're batching out stuff on an industrial scale, but I find myself using it all the time.
I jointed the stick straight, planed it for thickness and width, used a shaper to chamfer and the side dados. Sled jig with stop to cut to length, then sled jig with shaper for end dados. I built a carousel jig for the bandsaw for the rough radius, then used a belt sander with a right angle table to smooth them out.
That's amazing!! This stuff always breaks my brain, I can barely cut a 2x4 square.
Thank you! Figuring out the process the first time around was...challenging. My first brilliant idea was to use a carousel jig with a big straight knife head on the shaper. All it made for me was splinters as every piece I ran through grenaded on me. After I cleaned out my pants, it was back to the drawing board.
Wow! Safe adventures to you. Looking forward to the finished product.
How did you make the individual tiles? They all look very uniform in size and shape. Clever use of chamfer bits on a router maybe? Looks very nice.
Thanks! I jointed the stick straight, planed it for thickness and width, used a shaper to chamfer and the side dados. Sled jig with stop to cut to length, then sled jig with shaper for end dados. I built a carousel jig for tha bandsaw for the rough radius, then used a belt sander with a right angle table to smooth them out. I make extensive use of micrometers and digital readouts in my shop; very accurate sizing is the key to getting something like this together without gaps.
Wow, I knew it took some work, but that's quite the process. I'm also happy to see I'm not the only person to use a shaper in my shop. I've heard the argument that they only make sense when you're batching out stuff on an industrial scale, but I find myself using it all the time.
Very nice. Please post pics of the finished piece!
Thank you. Will do.
Wow looks great! Do you have any pics of alternate angles?
Thank you! I do. I'll work on getting some other pics of the piece up.
How did you make the curved tiles?
I jointed the stick straight, planed it for thickness and width, used a shaper to chamfer and the side dados. Sled jig with stop to cut to length, then sled jig with shaper for end dados. I built a carousel jig for the bandsaw for the rough radius, then used a belt sander with a right angle table to smooth them out.
Ah, so for the carousel you oriented the tiles vertically on a large circle?
Ya. I think the math worked out to about an 18" disk.
Gotta ask.. Why not use veneer and actually weave it?
Primarily longevity. This is for an exterior entry door. Also, I find veneer work tedious. I stick with solids whenever possible.