St Jude Auction Bows are Underway

[Dan Bonner]

Now we need to drill the holes for the limb atachment. I use a micrometer to measure and then mark the bolt and pin holes. Next I use a tiny drill to make pilot holes in exactly the right spot.
 
the bigger bits follow thepilots and I end up with good bolt position.
 
 
pins are also on the money!
 
next I mark and cut the sight window on the BS. I cut it so the shelf is square.
 
 
Now I need to radius the shelf.
 

[Dan Bonner]

I make several passes with this bit to get it shaped to the line.
 
Now I need to get the cut passed center to a perfect 3/16". It takes several passes with each one a little deeper. I adjust depth by gently adjusting the table height on the DP.
 
after first pass..
 
after multiple passes its perfect.
I use the bandfile to smoothe out the shelf.
 
Gotta deal with the steps left by the burr.
 
 
 
Gotta love the speed and ease of the angle grinder with a paint removal sponge.

[Dan Bonner]

drilling out throat with 1.5" hole saw.
 
no the radius under the handle.
 
now follow the lines and cut outthe rest with the BS.
 
 
 
first I shape the throat on the spindle sander
 
more shaping
 

[Dan Bonner]

handle mostly shaped
  \\
 
 
 
 
 
Next step is making wedges. I do that in the next couple days.

[rbcorbitt]

Beautiful work, Dan!  These are going to be two fantastic bows!

[bowhntineverythingnh03743]

Thanks you Dan for sharing these steps in shaping a handle... I find that handles are very difficult to do so seeing the steps really help!!! Well done!

[Trux Turning]

Thanks for the pics! Those risers are sweet- the lams are going to really look great

[Dan Bonner]

A little more Progress. Got both sets of wedges built. I learned a quick and easy method several years back for building perfect wedges every time from Steve Quinton of Ibex bows. It uses my trusty 6x48" Harbor Freight beltsander and a simple jig.Heres how it works...
First i cut my stock to the length and width I want for my wedges. I this case its .3" x 9"
 
 
 
 
Heres where it gets interesting. I rip a 36 grit down to about 4" and put it on the sander. And use this simple jig that took about 15 minutes to make.
 
The jig is just a chunk of MDF with a wedge with the dementions I want that is split in half and glued on either side of the MDF. I clamp my wedge stock to it and use the exposed roller as a guide to make the wedges. The belt runs in between the guides. All of this took maybe 20 minutes.
 
 
 

[Dan Bonner]

The wedges always turn out perfect!
 
  .
Also cut some burrs off for limb bolt nobs.
 
 
 
These are premium South TX antler burs BTW...

[Horne Shooter]

Looking very nice!

Looking forward to shooting it...

[Pat B.]

Sweet !

[whitehat]

really sweet!

[heartlandbowyer]

Dan, nice jig, I can see my wedge grinding just got easier.
These bows are gonna look amazing cant wait to see the ending of this thread.

Cory

[Trux Turning]

Great build! Looking forward to seeing how you do the limb bolts.

[Horne Shooter]

It looks like Whitehat and I will be meeting up  with Dan in July in New Braunfels, Texas to pick up our St. Jude's bows and wood arrows.  Should be great!

[Dan Bonner]

OK Paul's bow is only needs finish and its done. Lots of work and pics to post so I wont elaborate much. If you have questions just ask.
First Stripstrike came by and elped me clean up the shop.
 
 
then I got on with the limb bolts
 
5/8 forstner bit
 
 
 
 
tips and overlays
 

[Dan Bonner]

 
 
 
 
 
 
 

[Dan Bonner]

 
 
 
 
 
Important point here. I uses 7 mil painters plastic (home depot) and Fibertape (walmart) to keep my lams from slipping and getting glue everywhere. works great.
 
 

[Dan Bonner]

Hose on back so I do all the overlays at glueup.
Use zipties to pull lams into form (very easy)
 
 
 
Built my form using a condensation pan heater under .040 stainless sheet with a timer and a thermostat. Its a killer setup. Set the temp, set the time and go on to something else.
   

 
 
 

[Dan Bonner]