Newest Baltic Birch Ply Scroll Saw Shell

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Project by alwaysscrolling posted 03-12-2016 11:27 PM 4336 views 6 times favorited 13 comments Add to Favorites Watch

Made another Scroll Saw Shell out of Baltic Birch Ply. I used 6 wedges on this one which resulted in 72 segments. The overall length of the Shell opened and before the gluing stage is over 43”. The mouth opening measures 9.5” wide and it is 8” deep by 9” high. The finish is approximately 8 coats of spray poly. The stand is made from the left over pieces of the wedges of the shell parts. They are a lot of fun to make. Thanks for looking. Ron

13 comments so far

View toyguy's profile


1758 posts in 4998 days

#1 posted 03-13-2016 12:37 AM

I just love these things. One day I am just going to have to give one a try.

-- Brian, Ontario Canada,

View Bob Collins's profile

Bob Collins

2847 posts in 4845 days

#2 posted 03-13-2016 01:09 AM

Very nice, like the use of plywood on these shells. Great finish.

-- Bob C, Australia. Your best teacher is your last mistake.

View bobasaurus's profile


3733 posts in 4345 days

#3 posted 03-13-2016 02:12 AM

That seems like a ton of work. No idea how you make all that on a scrollsaw.

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

View htl's profile


5519 posts in 2320 days

#4 posted 03-13-2016 02:25 AM

These are just so cool!
Would love to make one some day.
You’ve made enough of them now, you’ve got it down pat.

-- An Index Of My Model making Blogs

View pottz's profile


18776 posts in 2145 days

#5 posted 03-13-2016 02:33 AM

ron you rock man that is just plain cool dude.welcome to lumber jocks and I cant wait too see more of what you do.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View oldnovice's profile


7709 posts in 4529 days

#6 posted 03-13-2016 02:47 AM

That is one beautiful she’ll … the finish is just outstanding.
I really like the direct frontal view.

-- "It's fine in practise but it will never work in theory"

View Chad's profile


19 posts in 1972 days

#7 posted 03-13-2016 12:30 PM

Wow! I have no idea how you did that on a scroll saw! Amazing work!

View greyspider's profile


102 posts in 4084 days

#8 posted 03-13-2016 12:41 PM

I love these shells. I just acquired a DeWalt scrollsaw and would like to make one of these. Could you please point me in the right direction? Thanks


View alwaysscrolling's profile


20 posts in 2003 days

#9 posted 03-13-2016 05:44 PM

Many thanks for all the great comments. Again these are a lot of fun to make and the cutting process is not as difficult as you may think. I believe the cutting process of all parts to make the shell is somewhere in the ballpark of less than 6 hours. That’s the easy part. The gluing, shaping and sanding stage is where the real time takes. Overall I have approximately 30 hours in this Shell.

For those interested in learning more, Steve Garrison has an e-book available which will provide more detail than you can imagine. If you look at facebook and search for Scroll Saw Shells you will find a dedicated section to these Shells. There you can also find details on info on his e-book. You can also go to Youtube and search Scroll Saw Shells and find video instructions on how to make them. Someday I hope to make a video and post it there as well. Always willing to share info as needed. Thanks again, Ron

View helluvawreck's profile


32122 posts in 4028 days

#10 posted 03-13-2016 07:17 PM

This is a real beauty. Congratulations.

helluvawreck aka Charles

-- helluvawreck aka Charles,

View Diggerjacks's profile


2330 posts in 4300 days

#11 posted 03-14-2016 07:25 PM

Hello Ron

Another fantastic scroll sawing work
I like it very very very nice

Thanks for sharing

-- Diggerjack-France ---The only limit is the limit of the mind and the mind has no limit

View Tsharp's profile


16 posts in 2028 days

#12 posted 03-20-2016 11:25 AM

Ron, this shell is on my top 3 favorite LJ projects I’ve seen yet! The Baltic birch really gives it a unique touch

-- Todd Sharp

View alwaysscrolling's profile


20 posts in 2003 days

#13 posted 03-20-2016 05:49 PM

Many thanks again for all the great comments. I am presently working on another Baltic Birch Ply Scroll Saw Shell. This one will be about 1/3 larger than the one posted. Just wanted to see the results of going larger. Will have it posted soon. About 90% complete. As mentioned, these are a lot of fun to make. Ron

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