64" d/r buildalong for Brandon DONE !!

[kennym]

My middle son was home on leave this past week and liked my new design of d/r so much that I agreed to make him one. Since there is no hurry(need to have it done by spring 2010...)I thought I would try to take enuff pics to do a decent buildalong....

Here is what he decided on for wood,laid most of it out on the bench here. Coco riser with black glass canine accent,jatoba belly,some zebra .025s that have broken corners(can't sell em) and clear glass. Will have walnut edge grain core,but didn't get it in this pic.....

   

Notice the coco has a little defect also,I'll try to work around it    

[TimZeigler]

   Thats gonna be nice Kenny, can't wait to see how this one progresses.

[Trux Turning]

I'll be watching- those woods should make a great looking bow.

[TNstickn]

[kennym]

Tonite,I cleaned up the riser and cut all the rough and wax off,then ran it thru the thickness sander to get 1 5/8" x 2" riser block.
 

Then marked center on the riser block and laid out the canine radius (with a 5 gal bucket top!! LOL)Also sanded the slick side of a .050" x 1.5" black glass for the canine accent(I wanted to put white in,but Brandon said black!)
 


Then cut all the lams for the bow cept the zebra which was already cut and sanded to .025"

Here is a .001"taper being cut by running a .001" sled thru the bandsaw along with the stock. This way you get side by side lams without grinding from parallel,which grinds away some of the grain structure. The lams bookmatch much closer this way!
 

The cutting sled...

 

Here the jatoba parallels go into the sander...

 

The inspector....

 

More Friday............  

[mwmwmb]

this is gonna be good. like the wood choice.

[TNstickn]

The inspector looks like nothin is gettin by without the proper specs!!      

[Dmaxshawn]

Looking real good kenny.

Shawn

[Apex Predator]

Get on with it man!  Can hardly wait!

[kennym]

Gotta get those orders out Marty!! LOL

Back to it this afternoon!

[kennym]

OK, had a bit of time (after mowing yard)  

 First thing,I sliced the riser to put the black glass canine in...
 

Then cut the glass to length,about 3/4" longer than each cut...
 

Now to true up glue surfaces...
 
 

The thin piece needs a backer to keep square,the big piece works just right...
 

Only 1 gap,off to the sander to adjust.....
 

[kennym]

Now to pin the end to keep slippery parts in line!! Note I have marked the riser cut line so you can see I don't drill into the part to be used(note toothpick to right of drill bit)....

 

Laid out ready to glue...

 

The alignment pin in action....

 

Clamped up,,first I lay a piece of wrap on the bench and apply glue to all parts. Elongate the alignment holes a bit for the angle,then you can move parts to line up centerline while clamping.

Squeeze the parts together by hand,wrap the plastic over,then apply 1 quick clamp in the middle. Then the osage blocks and spring clamps hold parts in line side to side. Then start clamping back to belly way while adjusting centerline and whatever else needs it. Good thing smoothon doesn't dry too fast!! LOL

 

[wihill]

Looks great so far, Kenny!   Man I love these build alongs.   :D

[razorsharptokill]

Yesss! I've been waiting for this!

[razorsharptokill]

Do you put an index at each end of the accent?

[Dmaxshawn]

Thats a handy tip on the indexing Kenny thanks.  

Shawn

[kennym]

Jim, I only pinned the end with the narrow pc of riser on this. Not sure I could get two pins to line up! The little osage blocks and spring clamps keep it side to side,so only really need 1 pin.

[wyatts daddy]

The pin idea has just saved me a ton of time, you are the man.
Bill

[kennym]

All righty,back to it.

Got the riser out of the clamps and cleaned and squared up. Marked out the shape and the exact length,I leave it long during accent glue up til I get ready to cut profile on it......
 

Now to splice the lams. I just clamp a square block on the disc sander table at an unknown angle(pleasing to eye) to skive the lams. Figure the side you want showing and push them BOTH in the jig til it grinds the one close to the wheel to a feather end. Then swap places with them and grind the other one. If you run them both at the same time,the angle will match perfectly.
 
 

The results...
 

 

Lay a piece of plastic on a strait bench or board,lams on top of it and apply CA,you have time to work with it if you coat both pcs.....
 

Line up the lams,being sure to check full length straightness,flip the plastic over,add a clamp block and clamp. Give it 20 minutes to set,and take out and sand off any glue.
 

[kennym]

Got the fades ground, 1/16" at 1" from tip,1/8" at 2" from tip........
 

Then I put a stop on the flat of the riser with 2 spots of CA,to give a place for the lams to push up against. It is roughly the thickness of the belly veneer, .001" taper and glass combined...
 

Got the form prepped,silicone spray first,then plastic wrap....
 

Here are the parts laid out ready to go....
 

Glue is mixed,those are plastic bathroom cups,takes me 1 3/4 cup of each part of the smooth on to glue up a bow with 4 prs of wood lams and 2 pcs glass....
 

Here my bro applies the glue with a simple paddle. In this pic ,he is gluing the last veneer to go on the belly.