MAKING
PATTERNS (TEMPLATES):
You really need a power bandsaw or jigsaw to make special template
designs. If the design is simple enough, you can use a coping saw,
but the power equipment will produce better patterns. Almost
any shape can be cut, although right angles will be slightly rounded.
You can cut out the surplus wood, however, with a good sharp wood
chisel.
Templates
are a 2-step operation. First, you will have to draw on graph paper
(1-inch grid squares) the design you want. Then you have to transfer
this design to the material that you will use for the templet-1/4-inch-thick
hardwood or hardboard. We suggest tempered hardboard because the
material is more dense and won't "fray" at the edges as much. Once
the pattern is on the hardboard (or hardwood or plywood) you can
cut the shape(s) with a jigsaw or coping saw. This is tedious work;
have patience and go at it slowly.
The critical
measurement is the distance between the edge of the template and
the inside edge of the cut. This measurement is always one-half
the diameter of the router bit that you will use and one-half the
arbor, pilot, or bushing diameter of the router.
As noted
above, a router cannot make an inside angle cut, which has to be
chiseled out by hand. And, the bushing diameter will be exactly
one-half of the bushing diameter from the template at all points.
A basic
guide for making templates is illustrated below. The letter X represents
one-half of the guide bushing on the router.
DROP
LEAF TABLE CUT:
The edges for a drop leaf table are tricky cuts. Take your time,
and we suggest that you try the cuts you want on scrap wood before
you make the real cuts.
You may
use a 3/8-inch bead and 1/4-rd. bit and a 3/8-inch cove bit for
the cuts. Or, you can use two 1/2-inch sizes in combination with
each other. The leaf edge of the cut is made with a cove bit with
the leaf upside down. The top edge is done with the bead and 1/4-rd.
bit. You should use a 7/16-inch pilot with both bits. In dimension,
make the X measurement a tad larger than the Y measurement for the
leaf. If your table leaf will be less thick than the top, raise
the bit by the difference between the thickness of both pieces.
Or lower it if the table leaf is thicker.
INLAYS/TEMPLET
BOX:
You need two matched templates for inlays. The male template to
cut the shape via through-cutting, and the female which is used
for routing to the thickness of the material (male) that you will
inlay. The illustrations will show you the basics of this cut. Practice
this first, before you cut the real inlays. We suggest a 1/4-inch
straight bit for the cuts. The male inlay should be about 1/64-inch
smaller than the female cut you make in the material. This is about
right for the adhesive.
The male
inlay box is created out of scrap wood; the male template serves
as the "lid." You will need a piece of scrap under the inlay material
for a clean cut, since you will be cutting through the inlay wood
to the scrap.
