Reply by hockeyfan_019

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Posted on Cutting Stars

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46 posts in 152 days

#1 posted 10-02-2020 07:07 PM

I actually created a sort of “rotary jig” last year, where you would screw down the wood blank to the base, and there was a “angled plate” on top where you put your router in place with a flat-ended cutter. You just had to fix the router plate at say “12:00” on the base, work the router to hog off material around 1 “arm” of the star, then rotate the top jig by 360/5=72 degrees, then repeat for the other 4 arms.

In theory it works, and I created several this way, but I think you will find accuracy is the key to a good result. If there are ANY discrepancies in the angles from arm1 to arm2 for instance, the result looks wonky. I was trying to make them for a wooden flag project, but in the end I just used the best one I made, created a silicone mold, and then cast a bunch more out of resin and painted them.

Getting all the angles reliable accurate and repeatable is very tricky for such a project. Good luck though!

-- Most of my tools are older than I am

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