Project: Business card holders #2: building an army

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Blog entry by jamsomito posted 12-08-2019 03:57 AM 444 reads 1 time favorited 0 comments Add to Favorites Watch
« Part 1: First project after a long break Part 2 of Project: Business card holders series Part 3: Sanding... »

Continued this project today. Getting close to done. Cut the pieces to size, then cut the slot on each. I put a couple stops on my sled that made it really easy to repeat for each of the 30 pieces. Only problem was the pieces were so small I didn’t feel comfortable holding them while cutting, so I had to clamp and unclamp each time. I could do about 5 at a time though, so it wasn’t so bad.

I had to tweak a few individual slots because my setup for previous steps wasn’t exactly ideal. I don’t have a jointer, planer, or drum sander, so I couldn’t get everything totally flat. No matter what I do, my ROS will carve a slight convex curve in the top of thin strips. I can’t figure out how to avoid this. If you have any tips I’d appreciate it. But, it really won’t affect these pieces in the end so I pressed on.

And in true “myself” fashion, I couldn’t leave well enough alone, so I decided to tinker with these a bit more. The prototype I made out of a 2×4 definitely warped on me over a day or so, and it didn’t sit flat on the table. So I decided to cut a couple curves that would give it 2 points of contact in the front and one point of contact in the back (concave curve on the bottom of the front piece, and convex on the back). It turned out pretty good!

Also in true “myself” fashion, I managed to skin a knuckle on my oscillating edge/spindle sander. I swear I have more injuries from sandpaper than any other tool in my shop.

After getting patched up, I finished the job.

I noticed my edge/spindle sander table left a bunch of black marks on about half of my pieces. Really not thrilled about that… Not sure why WEN would use a finish that rubs off. Guess I’ll need to give these all a quick hand sanding before finishing.

Also, I really think the back of the leg piece is calling for a logo of some sort. I’m thinking the company logo for the place these are going to. Going to try the acetone laser printer toner transfer method. Cross your fingers!

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