Hello, dear readers and homemade products!
Most often in the carpentry business it is possible to work with rectangular parts, somewhat less often – with round ones. But what if you need to cut, for example, an oval-shaped countertop?
Such a task requires a sufficiently high processing accuracy, and cutting a workpiece using an electric jigsaw, and then adjusting the edge to the line is too laborious and impractical.
In this article, the author of the YouTube channel “Hammer sound” will tell you how to make a special tool for a hand router that simplifies such tasks. The device can be resized to accommodate small workpieces.
This project is quite simple to implement in a small carpentry workshop.
Materials necessary for homemade.
– Film faced plywood
– T-shaped guide
– T-track tire (T-nut) < br> – Bakelite wing nuts
– Steel stud, nylon thread
– Wood screws with countersunk head, carpentry and second glue, sandpaper.
Tools used by the author.
– Manual router
– Milling cutters for wood
– Neiler electric
– Drills for wood with countersink
– Grinder, miter saw
– A set of files, pliers, hammer, vice
– Square, metal ruler, pencil.
– Protective gloves.
To set the movement cutters on an oval path, you will need a base with t-tracks, as well as a long guide made of plywood strip. Two sliders will move along the t-tracks, and it is they who will set the desired trajectory of the end of the guide (on which the router itself is fixed).
First of all, the foreman proceeds to sawing the aluminum T-shaped rails . In this case, a miter saw is used, although it is quite possible to do with a miter box and a hacksaw for metal.
To cut four pieces of the same length, the master fixes the limiting block with a clamp on the stop of the miter saw.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499344_ov-049.jpg" rel = "prettyPhoto"> The saw blade rotates at an angle of 45 degrees, and the first aluminum profile is cut off.
The same detail is turned upside down and the cut is repeated.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499349_ov-052.jpg" rel = "prettyPhoto"> This results in a 90-degree “nib” at one end of each of the four rails. Burrs can be easily removed with a file. Here it is necessary to process not only the outer edges, but also the inner ones – otherwise the sliders may catch on and the device will jam.
The base will be a square billet made of chipboard, or film faced plywood. Its thickness should be sufficient so that all guides are rigidly held on it. At the same time, you shouldn't make the base too thick.
The center and two diagonals are marked on the base. Guided by the markings, the master fixes the first segment of the T-track on it using a second glue. You can also attach it to thin double-sided tape.
The second track segment joins the first at an angle of 90 degrees. The author uses a square for accurate orientation. It is important that the ends of the guides, and especially the grooves, coincide as accurately as possible.
It is more correct to orient the third segment also relative to the first, but with the help of a long metal ruler. This will minimize intermediate measurement errors.
How you can see, and the last segment is oriented from the first one.
In T-tracks, pilot holes for countersunk screws must be prepared in advance. First, four self-tapping screws are screwed in near the center of the cross, and then along the edges. After screwing, you need to check the inner corners again.
The author pre-selected the thickness of the plywood so that it would be equal to the height of the aluminum profile. The final details of the base will be four isosceles right-angled triangles.
These details are glued to the base, and additionally fixed to it with nails using a nailer.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499368_ov-089.jpg" rel = "prettyPhoto"> Excess corners on the bottom of the base are cut flush with the ends of the profiles.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499334_ov-098.jpg" rel = "prettyPhoto"> A couple of these T-nuts serve as the basis for the runners… Their corners must be rounded so that they go smoothly in the guides.
< img class = "aligncenter" alt = "How to make a tool for cutting ovals with a router" src = "https://usamodelkina.ru/uploads/posts/2021-05/1620499314_ov-101.jpg"/> < a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499347_ov-106.jpg" rel = "prettyPhoto"> The most important place is the center of the crosspiece. In it, the runners should not jam, cling.
С the bottom side of each nut is screwed in a countersunk screw, and wing nuts will be used to hold down the plywood rail.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499338_ov-113.jpg" rel = "prettyPhoto"> For in order to mark the contour of the future cut, the author marks two centerlines of the ellipse with lengths of 1000 and 650 mm.
As you know from the school geometry course, an ellipse is a closed flat curve, the sum of the distances from each the points of which up to two points (foci of the ellipse) F1 and F2 are equal to a constant value.
The points of both foci on the long axis are marked as follows.
Now, carnations are driven into both centers and the end of the perpendicular.
Long a nylon thread is looped around three studs and tied into a ring.
A carnation at the end the perpendicular is removed, and now you can mark the ellipse.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499322_ov-033.jpg" rel = "prettyPhoto"> The prepared base must be oriented along the marked axes. They should line up with the center lines of the guidelines.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499333_ov-119.jpg" rel = "prettyPhoto"> You can attach the base to the workpiece in different ways, even with double-sided tape. In this case, the author attaches it to the underside of the future countertop. To do this, through holes are drilled in the base using a wood drill with countersink .
Then screws with a countersunk head are screwed in. Their hats should not protrude above the surface.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499339_ov-122.jpg" rel = "prettyPhoto"> The wizard inserts both sliders into the T-tracks, and places the first in the center, and the second on edge.
A long plywood strip is applied to them, which will serve as a guide. Holes for screws are marked and drilled on it.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499317_ov-132.jpg" rel = "prettyPhoto"> Now the guide is put on the screws and fixed with wing nuts .
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499370_ov-141.jpg" rel = "prettyPhoto"> Reduce the length of the guide to fit the ellipse.
Two steel studs are required to attach the router to the guide.
Each of the studs is alternately fixed in the chuck of the drilling machine, and one of the ends is sharpened under the cone.
Both pins are fixed in the sole of the router.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499279_ov-159.jpg" rel = "prettyPhoto"> The master made a rectangular strip of plywood trim. Its width should be equal to the total thickness of the base.
This the block is pressed against the sharp ends of the studs. After a light blow from the mallet, the centers of future holes are formed on the workpiece.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499350_ov-171.jpg" rel = "prettyPhoto"> Having drilled holes in the block, the author fixes both studs in it, fixing them with nuts on both sides.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499366_ov-176.jpg" rel = "prettyPhoto"> The whole construction is assembled as follows.
The guide is glued to the bar. To secure the connection, the author drills holes and tightens a couple of self-tapping screws.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499340_ov-198.jpg" rel = "prettyPhoto"> All ready, it remains to install a straight cutter for wood on the router, and align its edge with the line of the ellipse (from the outside).
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499311_ov-208.jpg" rel = "prettyPhoto"> Milling is performed in several passes, they are done clockwise.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499296_ov-216.jpg" rel = "prettyPhoto"> < a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499295_ov-223.jpg" rel = "prettyPhoto"> Author performs these works on the joinery.
The last pass, and the oval table top is ready for further processing steps.
< a href = "https://usamodelkina.ru/uploads/posts/2021-05/1620499365_ov-236.jpg" rel = "prettyPhoto"> I thank the author for a simple but useful device for a carpentry workshop!
Good mood, good health, and interesting ideas to everyone!
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Author's video can be viewed here.
Hello, dear readers and homemade products!