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Though I am in the middle of my 13 flag cases I am already working on the design for my next project - a curved side Arts & Crafts mantle clock. I'm planning on building at least two, one in mahogany and one in QSWO - maybe one in walnut also - and I am trying to figure out the best way to form the curved sides. I am taking styling cues from several other clocks I like so's not to strictly copy anyone else's design A little math first, then I can review some ideas I came up with.
The clock will stand about 16" tall, 9 3/4" wide and 5 1/2" deep. The face of the legs is 2" wide at the bottom and 1" wide at the top. The inside of the leg is perpendicular to the top/bottom, only the outside curves. The sides are 1/2" thick at the top and bottom, 3/4" thick near the center - I say near because I have not yet decided on the shape of the arc.
Since I am building multiples, and may have cause to build another someday, I may build a jig for the router table to shape the legs - maybe - as two of my solutions below would not require a jig for shaping the legs.. Now, the challenge of shaping the sides.
For the most part, getting close to the final shape using the bandsaw seems the best course of action should I decide on a single solid piece. The shaping afterward is what I am giving some thought to.
I am leaning towards solution #4 providing there are now grain issues curving across the face.
Thoughts?
The clock will stand about 16" tall, 9 3/4" wide and 5 1/2" deep. The face of the legs is 2" wide at the bottom and 1" wide at the top. The inside of the leg is perpendicular to the top/bottom, only the outside curves. The sides are 1/2" thick at the top and bottom, 3/4" thick near the center - I say near because I have not yet decided on the shape of the arc.
Since I am building multiples, and may have cause to build another someday, I may build a jig for the router table to shape the legs - maybe - as two of my solutions below would not require a jig for shaping the legs.. Now, the challenge of shaping the sides.
For the most part, getting close to the final shape using the bandsaw seems the best course of action should I decide on a single solid piece. The shaping afterward is what I am giving some thought to.
- I can build a second jig and using a large flush trim bit I can shape it in two passes, one from each side. The issue I see here is that there is a lot of exposed bit so I need a stout jig that both keeps my hands far away and holds the work VERY securely. Also, I will be routing across face grain - seems like an invitation for tear out.
- Same as #1, but attach the side between the legs before routing and use the edge of the leg as the guide for the bit. Same issues as #1.
- I can band saw the sides and use my 4" stationary belt sander to rough it down then use a scraper and finer grits to bring it to final shape. lots of work and dust, but avoids tear out issues. I don't have one of those fancy planes that can be adjusted for curves. Also, in not using a jig I may introduce small variations in the overall shape of the leg/side assembly. Don't know how noticeable that might be, but since I am planning to sell these near the $500 mark I want them to look perfect.
- Same as #3, but mount the rough shapes legs to the sides and bandsaw all at same time. Advantage here is no fussy glue up trying to align curved surfaces.
- Use a secondary wood to form the sides and veneer the primary wood to it. The advantage I see here is (especially with the QSWO) I won't be exposing little bits of end grain across the curved face. Don't know if that is really and issue, just being cautious.
I am leaning towards solution #4 providing there are now grain issues curving across the face.
Thoughts?