In the light #3: Precision sizing and clean-up of pattern pieces

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Blog entry by BritBoxmaker posted 08-04-2013 02:56 PM 2092 reads 4 times favorited 6 comments Add to Favorites Watch
« Part 2: So the story begins Part 3 of In the light series no next part

When I left you I was just about to cut all the pattern pieces. Well I did this successfully and cut all the pieces 2 mm longer than necessary, to allow for clean-up. With pieces 6 mm x 3 mm its very difficult to avoid split out on the cut, even with an 80 tooth cross cut blade. The two mm allows for precision sizing as well.

First to clean up the 45° ends. Here’s my belt sander, 915 mm x 100 mm belt. 180 grit for this job.

Surrounded by the usual clutter. The mitre gauge for it is like this

All very well but over the years there has been some wear to the sliding bar

which means it could be out +/- 0.5°. Too much for my liking. So to build a jig. I machined a 16 mm x 6 mm piece of Oak to fit the slot

and cut a piece of 9 mm Birch ply to the same size as the table

I secured this to the sliding bar with three screws. Gapping it from the belt by 0.6 mm using a piece of veneer. Then using my 45°, 60°, 120° and 135° perspex template (still accurate, I checked it and its within 1’ (1/60th °) of true) I marked a nominal cut line across the top plate

Unscrewed the top plate and cut the piece into two. The left piece screws precisely into the original two left hand screw holes (verified with 45° template).

Next the gapping for the two pieces, done with some leftover 6 mm x 3 mm strip from the pattern cutting).

and the right side piece was screwed down to the sliding bar (gapped from the belt with veneer again). To use you simply put the piece to be cleaned up in the slot

and use the long (gapping) piece as a push stick to feed it forward

holding the piece being sanded down with another piece of scrap

with the jig slid from left to right the push stick can be used to push the piece out of the jig, when clear of the sanding belt

Two test pieces glued (CA glue) to show accuracy of the 45° finish.

More sanding to finish length in the next part

Be seeing you

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

6 comments so far

View Sheila Landry (scrollgirl)'s profile

Sheila Landry (scrollgirl)

9238 posts in 3280 days

#1 posted 08-04-2013 03:53 PM

Making the proper jigs is a great asset! thank you for sharing this with us. :)


-- Designer/Artist/Teacher. Owner of Sheila Landry Designs ( Scroll saw, wood working and painting patterns and surfaces. "Knowledge is Power"

View RogerBean's profile


1605 posts in 3313 days

#2 posted 08-04-2013 04:07 PM

HI Martyn,
Nicely done. Another lesson in precision.

-- "Everybody makes mistakes. A craftsman always fixes them." (Monty Kennedy, "The Checkering and Carving of Gunstocks", 1952)

View grizzman's profile


7836 posts in 3663 days

#3 posted 08-04-2013 05:09 PM

yes , i agree with shelia and roger, the example here is to make the proper jigs to get good results and is the key, thanks for the fine idea here , its always enjoyable to see how another woodworker achieves good results. grizz

-- GRIZZMAN ...[''''']

View Druid's profile


2055 posts in 3155 days

#4 posted 08-04-2013 08:49 PM

Nice clear explanation, and very useful for many other applications. Thanks for sharing.

-- John, British Columbia, Canada

View Roger's profile


21001 posts in 3164 days

#5 posted 08-04-2013 11:57 PM

Good one. Jigs are a must, for sure

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View mafe's profile (online now)


11957 posts in 3449 days

#6 posted 08-08-2013 01:03 PM

Clever jig.
The right jig is half the work or do we say, measure twice jig once and then sand.
Smiles to you.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.

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