Construction Grade Toys #4: Making Fenders ¡Ay, Caramba!

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Blog entry by sIKE posted 08-28-2011 02:59 AM 10427 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 3: Little more work done Part 4 of Construction Grade Toys series Part 5: Almost there »

Stalled out a bit making fenders,. At about 1.5 hour a pair and then the router ate a couple of pairs and then one pair were not even close to a match, then another pair the wood fractured.

Here is a couple of pics of my first attempt. You can see one of the ways of working with small pieces is to mount you hand held tools like my ROS upside down and bring the piece to it.

The fenders turned out very nice but then the router ate them.

On the final attempt I then decided to glue the blanks together and then cut and shape them as one. This worked like a champ… here are attempts 8 and 9 at the bottom of the pic….

To resolve the issue with pieces tipping into the router bit I mounted a scrap piece of thin plywood across the router table and slowly raised the bit through the ply to make a zero clearance insert. I still got a small amount of cross grain tear out, but nothing that a little sandpaper cant clean up.

-- //FC - Round Rock, TX - "Experience is what you get just after you need it"

3 comments so far

View PurpLev's profile


8652 posts in 4896 days

#1 posted 08-28-2011 03:03 AM

ah yes…. working with small parts… a whole different ball game than ripping and cutting large furniture size components isn’t it? pair 8,9 looks great!

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View William's profile


9950 posts in 4090 days

#2 posted 08-28-2011 08:26 PM

This is why I only do miniature parts on my scrollsaw and then sand them by hand. I tried making small parts using things like my table saw, router, and such. After my hearts stopped fluttering from the scare I got and I went to change my britches (you know why), I declared never to try that again. The scroll saw is perfect for small tasks and a lot safer. I have often accidentally shoved my finger into the scroll saw blade while doing tiny parts. I have scratched my thumb pretty badly a few times, but never went deep enough to bring blood.


View sIKE's profile


1271 posts in 5002 days

#3 posted 08-28-2011 10:34 PM

Yeah, once you get out past “square” the table saw/miter saw/radiam arm saw get to be quite scarry devices of destruction, I have a very small blade on my benchtop band saw and have quite an aggressive blade on the scroll saw…..

-- //FC - Round Rock, TX - "Experience is what you get just after you need it"

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