I guess I used this step as a lesson to myself on how to remove a lot of material fast. Having never done anything like this before I thought I would try different methods.
The first method was route channels leaving some uncut material to support the router and then use my flush cut saw to remove them. Then I thought of all the dust that would make so I tried to make a bunch of saw cuts and beat them out with a hammer. This worked very well at limiting the amount of chips.
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But when I used the router I was scared to death of slipping near the and ruining the entire thing.
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Then I tried to use a stationary router in moving jig. This is the jig that I used to flatten my work bench.
But once again I was afraid when I got to the ends because I was cutting blind.
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This is the method I ended up using. A stationary jig with moving router. It was very effective and relatively fast.
I made it with hardwood sides the keep it from drooping in the middle and melamine to reduce friction. Another thing I did for safety was to install stops. One on each end to limit the travel of the router and in the lower picture to keep the jig in position.
I just lined it up in the center and made a cut and then rotated the jig around the center point looking through the slot to position it. I also used an old candle to wax the bottom and edges or the router to make it slide very easily.
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The slot was about 2” wide allowing me to make two passes, with the 1 1/2” bottoming bit I used, before re-positioning the jig. One half a rotation of the jig and I was done with the first pass. I took about 1/4” of material off at a time.
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It ended up taking me about 1/2 an hour of cutting to complete it.
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After a little sanding with 40 grit
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And Last but not least 1/2 of the pile of wood removed with router. That’s an 18” scale.
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Next time I will start with the stand. Like I said in the beginning it will be something different.
-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX
24 comments so far
cobra5
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154 posts in 4240 days
#1 posted 05-10-2009 10:12 PM
thanks for the inspirations,
-- tool time tim aka "cobra5"
Rj
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1047 posts in 3902 days
#2 posted 05-10-2009 10:14 PM
Wow Gary That looks great! it will be exciting to see it when your finished .
Thanks again for filling us in on the process . (I’m learning alot from your posts)
-- Rj's Woodworks,San Jose & Weed Ca,
Dick, & Barb Cain
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8693 posts in 4570 days
#3 posted 05-10-2009 10:15 PM
That’s sure going to be a beautiful table.
-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
a1Jim
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117468 posts in 3848 days
#4 posted 05-10-2009 10:15 PM
Very nice Gary looking forward to more progress
-- https://www.artisticwoodstudio.com/videos wood crafting & woodworking classes
lew
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12563 posts in 4026 days
#5 posted 05-10-2009 10:22 PM
Gary,
Thanks for sharing the trip to what is going to be one beautiful table!!
Lew
-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.
tenontim
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2131 posts in 4015 days
#6 posted 05-10-2009 10:31 PM
This has been a very informative series, Gary. I can’t ever see myself making this style of table, but the methods that you used are very interesting. Hopefully they’re filed away in the brain bank and can be retreived at a later date. Thanks for all of the post on this.
Scott Bryan
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27250 posts in 4093 days
#7 posted 05-10-2009 10:33 PM
Your ingenuity and resourcefulness never ceases to surprise me. Many of us, I know I would fit in that category, would have settled on a removal technique at the start of the process and doggedly stuck with it rather than stopping midstream to evaluate things and try to come up with a more effective process. And building a jig in the middle of things!!! That interruption only slows you down- right?
Nice job, Gary. Thanks for the post.
-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine
pommy
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1697 posts in 3962 days
#8 posted 05-10-2009 10:51 PM
as always gary you look at the bigger picture i was talking to fellow lumberjock on saturday ( philip edwards )at a local wood show
and i told him how wonderfull i think your work is thank you for show us mear mortals how to do things properly
andy
-- cut it saw it scrap it SKPE: ANDREW.CARTER69
DocK16
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1186 posts in 4358 days
#9 posted 05-10-2009 10:57 PM
I have been waiting for each episode to be posted since you announced the project. Several good ideas to hog out the waste but the final method I think is the best. Can’t wait to see the base I’m sure you won’t disappoint.
-- Common sense is so rare anymore when you do see it, it looks like pure genius.
Napaman
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5530 posts in 4348 days
#10 posted 05-10-2009 11:11 PM
wow…that is amazing…you said half an hour—-for all methods??? that seems fast…amazing..
-- Matt--Proud LJ since 2007
Joe Lyddon
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10439 posts in 4323 days
#11 posted 05-10-2009 11:33 PM
Hi Gary,
Very good progress!
I’ve gotta say… when I saw that circular saw cutting slits, my first thought was “Oh No!”... I was happy to see how you modified your method.
Your final solution is very similar to a fixture I made called Router Skiis. For the average project, it works pretty well.
See more about it at… http://www.ncwoodworker.net/pp/showphoto.php?photo=24057
Your Top really turned out GREAT! Thank you for the progress reports!
Now, for the part that holds it up! :)
-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"
SCOTSMAN
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5849 posts in 3856 days
#12 posted 05-10-2009 11:40 PM
Great Job as usual gary well done laddie Alistair
-- excuse my typing as I have a form of parkinsons disease
Karson
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35158 posts in 4671 days
#13 posted 05-10-2009 11:42 PM
Can you take the chips back gary and ask for your money back. Tell them it was not needed.
Great job on the flattening. and removing.
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected] †
Lee A. Jesberger
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6866 posts in 4250 days
#14 posted 05-11-2009 12:14 AM
Hi Gary;
I’ve been watching with interest in how you did the top. As usual, your work is Masterful.
Hollowing out the center is a scary process, huh?
A suggestion if you don’t mind. If you are going for an 18th century look, the outside or “crust” looks a little on the bulky side.
That has a lot to do with our decision to carve the edges, when we were building one:
http://lumberjocks.com/LeeJ/blog/1628
Great work!
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
CanadianWoodChuck
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402 posts in 4184 days
#15 posted 05-11-2009 12:24 AM
Excellent progress report Gary – it will be beautiful. I love your flattening jig. Thanks
-- Wood Chuck (Bruce) http://3dwoodworkingplans.com
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