Wood Magazine 87 by Larry Clayton
Author:Larry Clayton
Language: eng
Format: epub
Tags: Wood, Home and hobby woodworker
Publisher: Meredith Corporation
Published: 1996-03-25T05:00:00+00:00
I Cut a piece of walnut !/>x9xll". Rout a W' cove around one face, using a table-mounted router and a piloted cove bit. Rout a keyhole hanging slot on the back. Finish-sand the board. Later, you'll mount the scrollsawn sign on it.
EXPLODED VIEW
Western Welcome Plaque
•A" stock
V2" stock
2 Photocopy the full-sized pattern in the WOOD PATTERNS ™ insert in the middle of the magazine. Adhere the copy to !4x8xl0" stock. Either Baltic birch plywood or solid stock such as basswood or poplar would be suitable.
3 Drill K16" blade start holes where shown. Thread a #4 scrollsaw blade (.035X.015", 15-18 teeth per inch) through the hole in the horse's mane.
4 Saw along the inside line of the mane, leaving the shaded part of the pattern. Similarly cut out the inside portions of the tail, the trees, and the horse's body. Then, cut out the section between the horse's front and hind legs.
To cut a sharp inside corner, such as the one shown at 1 in the Cutting Sharp Turns drawing, saw into the corner from two directions. Make the first cut from the blade start hole into the corner, shown by the lower arrow. Back
70
WOOD MAGAZINE APRIL 1996
These wooden cutouts have the antique-metal look
the blade out to the start hole, then make an arcing cut through the waste area, shown by the curved arrow, returning to the cutting line just beyond Point 2.
To create a sharp point at 2 and begin cutting the next corner, 3, saw in from the cutout area along the lower dashed line. Complete the corner by backing the blade out to the start and making the cut shown by the dashed loop.
Continue cutting the remaining points and corners in the same fashion. The arrow at the top of the tree shows another path you can follow when cutting sharp outside points.
5 Insert the blade through the start hole in the letter O, and cut the center out of the letter. Starting from the hole near the W, cut out the individual letters and set them aside.
6 Cut out the rectangular area surrounding the letters at the bottom of the plaque. In the upper part of the plaque, insert the blade through the hole in the corner beneath the lefthand tree.
7 Cut around the tree's outside pattern line. Keep an eye on the inside edge as you work; this will help you maintain consistent width for the tree outline. Continue around the horse and the other tree, then cut along the inside edge of the frame.
8 Cut the sun out of the waste piece. Set it aside until later.
9 Glue the large cutout onto another !4x8xl0" piece of stock. Sandwich the glue-up between two pieces of 34x8x10" scrap-wood (particleboard or plywood would work fine), and clamp.
I 0 After the glue dries, saw around the outside pattern line. Glue the letters and the sun into place, referring to the pattern. I I After the glue dries, finish the sign to resemble old, weathered metal, following the finishing instructions on
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