54" Hybrid Build-Along

[JGR1269]

I decided to do a build-along of one of my 54" Hybrids. The riser will consist of Bocote with 15 layers of glass and phenolic. The limbs will be black glass with amber a-boo tapers and a piece of black coretuff between the tapers. I start with a nice block of Bocote that is 2"x2"x18".          
My bows are built on a 1 3/4" form so I can cut 3/16" past center with a slightly offset riser. I square up the riser block and cut it down to 1 3/4"x1 3/4" and I'll use the pieces I cut off in the riser lay up.
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I marked it with my template and cut it out on the bandsaw.  
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I attach it to my jig and sand the riser profile on the spindle sander with a rub collar.  
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   Then I check the fit on my form and check for gaps. A little extra time building an accurate jig makes this job a lot quicker.  [/url] [/IMG]  
Tomorrow I'll get my fiberglass and phenolic cut and ready for the riser glue up.

[rmorris]

Jon, I am really looking forward to your build along. You do some beautiful work form what you have showed so far. I hope all is well in your family and thanks again in advance for the build along.

[JGR1269]

Thanks for the kind words.

[Trux Turning]

Looking good- I'll be watching this one!

[chackworth3]

Looking good Jon!  Ready to see some more

[LESKEN2011]

I've been admiring your short bows. Glad to see one made by you step by step. Thanks!

[JGR1269]

Work till noon today and a little yard work before I can get back on it.

[JGR1269]

I decided to eliminate the 1/4" piece of phenolic and go with 4 layers of glass instead. I now have a total of 20 layers of glass and wood strips to glue up along with the riser. Gotta get the lawn mowed so maybe I'll get it glued up later.  
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[chall]

Thanks for posting this , looking forward to following progress.

[Mad Max]

I'am in

Looking forward to this.

[chackworth3]

Hurry up and get your yard mowed!!!   :D

[JGR1269]

Sorry Chris, I don't work as fast as you do. Since the pieces of glass are all random lengths I mark center on each one.  
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Then I put a piece of tape on my bench with a reference mark and stack them all in order.  
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After clamping them I mark center and drill a whole through all pieces.  
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I insert a stainless alignment pin to keep all these pieces aligned during glue up.  
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Next I clamp one of the pieces already drilled to the riser as a reference to drill a shallow hole for the pin. I mark the riser block and off to the drill press. This pin will get cut off flush and make glue up much easier. The black glass will make it invisible after completion.  
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I decided to leave out one of the 1/4" Bocote strips after I had already taken this picture.  

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It's pretty much ready now for glue up.

[JGR1269]

I vacuum 0ff all the pieces and mix up my epoxy.  
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I drilled a hole in a scrap board to insert my stainless alignment pin. As I apply the epoxy I can stack them in order on the pin.  
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I insert the stack of lams with the alignment pin into the hole in the riser and it's ready to put into the form and clamp.  
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Here's a shot of the clamp I built for clamping my riser to the form.  
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I use a bar clamp to squeeze the stack down then secure it in place with some zip ties and remove the bar clamp.  
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I bolt on my homemade clamp and a piece of 1/4" steel as a pressure strip. I remove the zip ties and begin cranking down the clamp making sure it's against the stops on the back side of the form.  
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Once I'm satisfied with the alignment I put it in my 16 year old oven for a four hour cook.

[bjansen]

Looking forward to this one. Its going to be a nice one.

[Trux Turning]

Originally posted by bjansen:
Looking forward to this one. Its going to be a nice one.

X 2

[chackworth3]

X 3

[JGR1269]

Out of the form and off to the spindle sander. I clean up and square the edges then clamp a fence on the get it true. I don't have any fancy tools and this is by far the most versatile piece of equipment I have used.  
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I set it back on the form with a light on the back side and check for gaps. Looks good so now I can mark and cut the belly curves.  
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A buddy just text and wants to go shoot some 3D's. Back at it later

[JGR1269]

I clamp my riser template to the riser block and mark my belly curves and fadeouts.
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Off to the bandsaw to cut the curves. I cut the wood portion with a good blade then switch to an old blade to cut the glass portion.  
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A few minutes on the spindle sander has everything square with a smooth curve.

 

 
The riser is ready for glue up so now I'll get my lams and glass marked, cut and ready to go.

[Dmaxshawn]

looking great

[JGR1269]

I attached these stops to each end of my form and I cut all the glass and lams to fit precisely between so they cannot slide. The lams, glass and aluminum pressure strip all slip under the metal piece on top of the stop.
 
I slide one end of the back glass against the top limb stop and follow the curve to the bottom limb stop and mark it for cutting.
 
I clamp a guide to the table on the disc sander and bevel the ends of the back tapers so I can glue them together for a less visible glue joint
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I clamp one of the tapers to the bench with a piece of wax paper under the glue joint.
 
A little TBII on the joint then slide the other taper into position until they match up perfectly. I clamp the other taper to the bench so it won't move then fold the wax paper over the top of the tapers and clamp a block of wood over the joint to cure overnight.