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23" jitterbug lure, wall hanger

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Blog series by grosa updated 11-10-2021 01:59 AM 15 parts 13613 reads 18 comments total

Part 1: Designing

09-08-2020 10:07 AM by grosa | 0 comments »

This is the original pattern i will be making.To start i taped 3 and 1/2 sheets of 8 1/2” x 11” paper together and drew out the perimeter of the shape, ended up looking good at 23” by looking at a reference photo i drew out the pattern and went over it with a black sharpie and adding color. I will re trace it onto a large piece of paper. From this sketch I will be able to make a 1/4” plywood template so i can put on my lath with a duplicator to turn the body and have t...

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Part 2: Glue up body

09-08-2020 09:09 PM by grosa | 0 comments »

The blank for the body will be made from basswood. I start with 4, 8/4 boards I flatten one side of the boards on the jointer. Next i go to the planner and just take off enough to make both sides smooth. Then i bring it to the wide belt sander and sand one pass on each side with 80 grit to rough it up for some glue. Making sure i have enough for the turning. Next i spread some tightbond wood glue and clamp it with pipe clamps. Need to let it sit for 24 hours before turning.

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Part 3: Prepping the blank and making templates

09-10-2020 12:58 AM by grosa | 0 comments »

Prepping the basswood blank I jointed one end square to the side and cut the ends off on the sliding table. Our sliding table saw has a 12” blade and has a maximum blade height of 4”. The blank is 8” so i will turn the stock 4 times to get a somewhat even cut. I did this at both ends and the blank ended up at 29”. Next i screwed on a face plate on one end and marked the center on the other. Then i clipped off the corners on the blank to make it easier to ...

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Part 4: Turning the lure body with a duplicator.

09-10-2020 10:41 PM by grosa | 2 comments »

With the duplicator mounted on the front of the lath you mount the blank between centers with a face plate on a blank this big. The template go’s in the 1/4” slot in the front of the duplicator and tightened down with thumb screws on the bottom.The duplicator has a stylus on one end to follow your template and a cutter on the other end that cuts your blank. I set the depth of cut. Make my first cut all the way across the blank to make sure i am parallel to the blank....

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Part 5: Cutting the aluminum bill.

09-20-2020 04:03 PM by grosa | 0 comments »

I clean the 1/16” thick aluminum with acetone and blow off the 1/2” thick template. Then i use double stick tape to mount the template to the aluminum, I am cutting the bill on an inverted pin router. I am using a 1/4” two flute solid carbide bit. The 1/4” pin drops down and rides against the template and at the same time the bit comes up from underneath the table to cut the material. I finish cutting the aluminum bill. It leaves a nice clean finish cut. ...

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Part 6: Working the bill and hook hangers

10-03-2020 12:49 AM by grosa | 4 comments »

This took a bit of time to do. It took a ton of passes on the English wheel on both sides of the bill to get the compound curve. Got the compound curve i was looking for. Now it is going to take a bunch of sanding to get out all them marks. I start with 150 grit all the way to 3500 grit. After sanding my fingers to the bone i used rouge with an 8” buffer. I started with the black rouge to remove most of the marks. Then i used the brown rouge to remove the smaller marks....

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Part 7: Making the eye socket jig and cutting it.

10-03-2020 01:29 AM by grosa | 4 comments »

To make the jig to do the eye sockets. Started by making a cradle to hold the giant body. Screwed two pieces of plywood on the ends then added a piece of plywood on the bottom. Then i put the jig vertical on the table saw and cut the ends 1 inch above center. When cutting the ends i set the blade higher than the plywood to score into the turning base so i would have a mark to know where i started in case i needed to go back to the beginning for any reason. Next i cut the sides to ma...

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Part 8: Cutting the flat on the chin for the bill

10-06-2020 01:27 AM by grosa | 0 comments »

Today i will be cutting a flat spot on the chin for the bill. I removed the ramps and one side of the jig. Using the center glue up line as the index i measured one side and screwed it to the jig. Did the same thing on the other side and screwed it in to secure it in place. Making sure that i am perfectly even i used the score line i made with the blade when i cut the jig. It needs to be 1 1/2” on both sides. Now i lay my original template over the body of the lure. I f...

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Part 9: Finessing the body to fit the bill.

10-07-2020 01:20 AM by grosa | 0 comments »

Next i need to finesse the cut to match the bill so theirs no gap and it’s a perfect fit. Making the body match the bill I need to line up the bill to the body. First i make sure body is 90 degrees to the table. I tape a center line and mark it on the bill. I prop up the body so the gap on top is less than the bottom gap until it looks good. Then i mark the outside edges with a sharpie marker. Next i put tape over the mark i just made and retraced it. I do this so the fil...

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Part 10: Making the eyeballs.

10-13-2020 12:41 AM by grosa | 2 comments »

Here is a picture of me holding the lure so you guys get an idea how big this jitterbug lure is. Making the eyeball i took some scrap Beech wood, squared it up and put it on the lath. Turned it to 2” diameter. Next i need to make a jig to hold the router over this turning. I start with some plywood cut roughly to size. A bottomand two sides. The bottom i mark out a square to fit the turning base. Next i cut out the square on the scroll saw. Check the fit. Next i cut t...

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Part 11: Primer

10-26-2020 09:05 PM by grosa | 0 comments »

This part of the build is a lot of work but very boring with not much to see. I started by using spot putty on all the minor defects and dents. Next i spray on white primer let dry for 2 days, sand smooth and repeat.I do this until i have 8 coats of primer.When all 8 coats are done i will start sanding with 220 grit all the way to 800 grit.

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Part 12: Making the eye to tie the line on the lure

11-04-2020 01:54 AM by grosa | 4 comments »

Finished the primer part of this build. While the primer is drying i made the line tie for the bill. I started with a sold aluminum rod, 1/2” x 12” long. I welded up a jig so i could heat up the rod and bend the loop. I used a regular map gas torch. When i was done closing the loop i flipped it over and put it on the upper half of the jig and straitened out the leg. Polished it up and set it aside. The line tie will be cut to length and put through...

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Part 13: Making the stencils for painting.

11-20-2020 12:55 AM by grosa | 0 comments »

This is the stencil material i use to make the stencils. Oramask 813. I trace my original drawing on paper then i cut it out. I will put this on the stencil material and trace it with a fine tip sharpie then i will cut the stencil. This is a mask to cover the white base coat and i will paint around it. I draw the pattern on the stencil material with a sharpie then cut it out with a razor blade only cutting the blue film and not the paper under it, It is a light tack back made fo...

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Part 14: Painting the lure part 1

12-12-2020 02:42 PM by grosa | 0 comments »

Masked off the eye. Painted it black. After unmasking. I masked off the eye socket and applied the face and wing stencil. Sprayed the brown and the black highlights over the stencil. Removed the stencil. Masked off the start of the eye brow. Eye brow unmasked. I will add to this latter. Working on the spots on the chest i placed the paper stencil in place. Sprayed it brown. Then i offset the stencil. Then i sprayed it black. The fini...

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Part 15: Making the line tie for the bill

11-10-2021 01:59 AM by grosa | 2 comments »

Put a piece of 1/2” aluminum bar stock in the lath and taped the threads on the back side. Then i turned it around and with a file i made a cone on the other end. Cut it off with a sawsall blade. Drilled and taped the eye screw, threaded a small 1/4 20 screw on the cap. This is how it looks. How it looks on the mock up. This is how it looks on the bill of the lure. It moves up and down freely on the bill just like the original lure.

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