Here's a question for all you gifted woodworkers, engineers, mathematicians, and just all around bright and talented folks. How would YOU cut out this oval and then inlay?
Obviously I did it but I am not happy with my ability to repeat the process again. I'm looking for a better more repeatable way. Here's what I did and the problems I had.
1st I made an ellipse cutting jig and cut the 1st "template" ellipse with my router:
Knowing that I would have to contour the underside of the template to match the curve of the serpentine front on the apron I used the 1st template to transfer the ellipse to a thicker piece of wood I could then contour the back of:
At this point the 2nd template was flat on the top. With a flat top the template would not transfer evenly to the apron as the thickness of the template varies as it follows the curve of serpentine apron. So the bit would cut fine in the center but not at all on the edges:
So I contoured the top of the 2nd template to also follow the curve of the serpentine front. I then went ahead and cut the ellipse into the apron. The BIG PROBLEM here was that as the router was riding the VERTICAL walls of the template it also started to tilt as I followed the contoured shape and this caused the bit the be in contact on the top of the template but actually cut about 1/8 inch inside of the template. Hopefully you can see what I'm talking about in the pictures
So folks... what's the right way to do this? I've talked with a few different folks that say the walls on the template would have to angle in to follow the angle as it changes with the serpentine front. How do you cut that?
How would you do it-- tell me all your secrets:gar-La; I'm just confused
Obviously I did it but I am not happy with my ability to repeat the process again. I'm looking for a better more repeatable way. Here's what I did and the problems I had.
1st I made an ellipse cutting jig and cut the 1st "template" ellipse with my router:
Knowing that I would have to contour the underside of the template to match the curve of the serpentine front on the apron I used the 1st template to transfer the ellipse to a thicker piece of wood I could then contour the back of:
At this point the 2nd template was flat on the top. With a flat top the template would not transfer evenly to the apron as the thickness of the template varies as it follows the curve of serpentine apron. So the bit would cut fine in the center but not at all on the edges:
So I contoured the top of the 2nd template to also follow the curve of the serpentine front. I then went ahead and cut the ellipse into the apron. The BIG PROBLEM here was that as the router was riding the VERTICAL walls of the template it also started to tilt as I followed the contoured shape and this caused the bit the be in contact on the top of the template but actually cut about 1/8 inch inside of the template. Hopefully you can see what I'm talking about in the pictures
So folks... what's the right way to do this? I've talked with a few different folks that say the walls on the template would have to angle in to follow the angle as it changes with the serpentine front. How do you cut that?
How would you do it-- tell me all your secrets:gar-La; I'm just confused