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Creating the Morgan #3: Creating the Wheel Space, Part 03

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Blog entry by DaveS2 posted 06-15-2022 03:43 PM 429 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 2: Radiator Insert Chapter 04 Part 3 of Creating the Morgan series Part 4: Spoked Wheels »

Today I am going to show a bit of the fabrication method I used to create the Wheel Space of the Morgan. The spare wheel resides on a slanted area on what we would call the trunk in the US. The plan provides all the necessary calculations and templates to create his part but it in no way describes just how to accomplish it.

There are a couple of ways to “git ‘er done”. First, if you have a large enough forstner bit, you can set the part of the correct 35 degree angle on the drill press and drill it to the correct depth. I didn’t have a bit 65mm or 2.5” so I opted for the Second method: Dutchy’s method of using a router, a template, and a top bearing pattern bit to make the part. I’ve used templates with a router for years so, for me, this was a no brainer.

The template can be made from MDF or ply or any material that is not too thick. . nothing over 1/4” or 5-6mm. As long as the bearing can ride along the template it will go well. If you don’t have a pattern bit, you can easily use a straight bit with a template bushing in the base plate. You will need to measure the thickness of the template bushing and add that dimension to the template cutout. NOTE: if the pattern bit cut length you have is not long enough, once the depth of cut will permit the bearing to ride on the edge of the actual cut out, you can remove the template and readjust the depth to meet the needed depth. The workpiece becomes its own template.

Here the template is attached with double stick tape and centered on the part, ready to be routed.

The top bearing pattern bit. It is designed to cut clean bottom areas and the bearing will ride on the template. A note: if you make the template out of MDF, my recommendation is that you coat the edge with a couple layers of thin CA. This will provide a tough surface that will hold up to repeated used. If this is a “one and done”, then the untreated edge is fine.

Set the router bit depth so that the bearing connects with the template edge and, beginning in the center of the piece, work the router round until the bearing full contacts the template edge and the rout around the template. This photo shows some of the initial passes.


The finished wheel space routed to the final diameter and depth. Note the clean, flat bottom of the well. The same result will be attained with the 1/4” (6mm) or 1/2” (12mm) straight bit and the router base bushing.

How Part 03, The Wheel Space looks when positioned on the chassis.

That finishes up this part of the blog. Hope this has been helpful. Please send me any questions, comments, or recommendations you may have.

—Dave

-- DaveS2, Canton GA aka pdwoodwerkz



5 comments so far

View Dutchy's profile (online now)

Dutchy

4397 posts in 3660 days


#1 posted 06-15-2022 03:58 PM


The plan provides all the necessary calculations and templates to create his part but it in no way describes just how to accomplish it.

- DaveS2

This is why a blog was also created.

-- https://dutchypatterns.com/

View DaveS2's profile

DaveS2

56 posts in 104 days


#2 posted 06-15-2022 04:34 PM

Jan,
I get the impression that I may have stepped on it with my blog. I never ever intended to discount your blog. My statement about the plans not giving specific instructions was absolutely correct and your blog does provide that information. My blog was meant to follow my journey on this build.

I heartily apologize if it seems I demeaned your blog or work. That was not my intent.

Regards,
Dave

-- DaveS2, Canton GA aka pdwoodwerkz

View crowie's profile

crowie

5521 posts in 3443 days


#3 posted 06-16-2022 12:08 AM

Good progress Dave.

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

View Eric's profile

Eric

5738 posts in 1365 days


#4 posted 06-16-2022 02:47 AM

Your getting there Dave, I’ll be following your build.

-- Eric, building the dream. the "Loft"

View Dutchy's profile (online now)

Dutchy

4397 posts in 3660 days


#5 posted 06-17-2022 11:59 AM



Jan,
I get the impression that I may have stepped on it with my blog. I never ever intended to discount your blog. My statement about the plans not giving specific instructions was absolutely correct and your blog does provide that information. My blog was meant to follow my journey on this build.

I heartily apologize if it seems I demeaned your blog or work. That was not my intent.

Regards,
Dave

- DaveS2

A little miss understeanding! I really like your blog!! I’m even glad with it. Keep up this good work.

My comment was on: but it in no way describes just how to accomplish it. Yes in the plan there is no discription, and that is one of the raesons I also made a blog. But all additions are more than welcome such as e.g. Steve his videos and in this case your blog, and as you mentioned everyone has their own method.

My response took a while, I was on a short vacation

-- https://dutchypatterns.com/

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