{"id":112,"date":"2014-04-13T19:59:55","date_gmt":"2014-04-14T02:59:55","guid":{"rendered":"http:\/\/projects.mykos.org\/?p=112"},"modified":"2014-04-13T19:59:55","modified_gmt":"2014-04-14T02:59:55","slug":"station-molds-2","status":"publish","type":"post","link":"https:\/\/blog.mykos.org\/?p=112","title":{"rendered":"Station Molds 2"},"content":{"rendered":"

\"station<\/a><\/p>\n

A couple of solid sessions in the shop and the station molds are all cut out and faired now. I’ll be so happy to finish working with plywood. It’s convenient and flat and dimensionally stable but it sure is awful to shape and cut nicely. I’ve had a lot of birch splinters in the last two days.<\/p>\n

\"felix<\/a>

Felix helps out.<\/p><\/div>\n

I got one of the farm cats to help layout the last mold. He didn’t really grasp the concept.<\/p>\n

The centre mold (#0) is the only one that isn’t cut as a double layer, since there’s only one of its size. It was a real treat to cut through only 1\/2″ instead of the full inch.<\/p>\n

\"gang<\/a>

Molds anchored together with brad nails.<\/p><\/div>\n

All the other molds were cut in pairs. You can see the brad nails sticking out here.<\/p>\n

\"cutting<\/a><\/p>\n

Part of the reason the process takes so long is you have to have your cut line off the table but still have the work supported. It makes for a lot of repositioning and reclamping. Straight cuts need a fence to be clamped on to keep the jigsaw on track. The fence needs to be 1-5\/16″ from the actual cut line so there’s additional layout for that.<\/p>\n

It would have been a bit faster if I wasn’t so fastidious about making the most of my plywood. I’m pretty cheap so when I\u00a0 spend $70 on plywood I like to make sure I’ll be able to use every bit of it. I could have cut each mold set off from its neighbours with the circular saw instead of working with the half sheet from each end but my scraps would have been dramatically smaller.<\/p>\n

I’m hoping to make a lot of the clamps and jigs needed for the rest of the build out of those scraps. Any leftover usable pieces will be a bonus.<\/p>\n

\"out<\/a>

Very much out of square.<\/p><\/div>\n

While I was cutting out station #3 I was doing half of it in a very awkward position. I knew I was putting too much lateral pressure on the saw but I was desperately trying to keep it from touching the line. At least the angle was going into the waste side. The result was this mold pair was quite out of square compared to all the others.<\/p>\n

Anyone doing this, take the time to make your cuts as smooth and close to the line as possible. It’s much faster than having to clean up the cut afterwards.<\/p>\n

\"sureform<\/a>

My friend the sureform tool.<\/p><\/div>\n

The tool that has proved indispensable for this work is the sureform tool. It’s like a small cheese grater that you use on wood. I had first envisioned using my spokeshave to do the cleanup and fairing of the mold edges. That’s what the ideal tool would be if these were solid wood boards. The plywood doesn’t shape very well at all with the spokeshave, and it dulls the blade very quickly.<\/p>\n

The sureform chews through it rapidly and leaves a surprisingly good finish for what it is. Blades are cheap and other than breaking off a few of the teeth it didn’t seem to change its performance at all throughout the job.<\/p>\n

So a lot of plywood grating got my high edge down into orthogonality with its reference face. Most of the molds didn’t need so much grating. Which makes them ready for this:<\/p>\n

\"sanding<\/a><\/p>\n

Most of the cleanup I accomplished with 50 grit sandpaper wrapped around a thin strip of cedar. I got the idea from Nick Offerman in one of his youtube segments of this canoe build. It lets you keep the sandpaper following the curve and prevents it from developing any flat spots.<\/p>\n

As you go you keep running your fingers along the edge to check for any peaks or hollows. That’s where you get the splinters.\u00a0Any big bumps get sureformed off and the small stuff gets smoothed down by the sandpaper. Peaks are easier to deal with than hollows. Luckily I kept my saw on the waste side of the line so didn’t have to deal with any glue-in repairs. A few came very close though.<\/p>\n

\n","protected":false},"excerpt":{"rendered":"

A couple of solid sessions in the shop and the station molds are all cut out and faired now. I’ll be so happy to finish working with plywood. It’s convenient and flat and dimensionally stable but it sure is awful to shape and cut nicely. I’ve had a lot of birch splinters in the last […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[2],"tags":[],"class_list":["post-112","post","type-post","status-publish","format-standard","hentry","category-huron-cruiser"],"_links":{"self":[{"href":"https:\/\/blog.mykos.org\/index.php?rest_route=\/wp\/v2\/posts\/112","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/blog.mykos.org\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/blog.mykos.org\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/blog.mykos.org\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/blog.mykos.org\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=112"}],"version-history":[{"count":4,"href":"https:\/\/blog.mykos.org\/index.php?rest_route=\/wp\/v2\/posts\/112\/revisions"}],"predecessor-version":[{"id":116,"href":"https:\/\/blog.mykos.org\/index.php?rest_route=\/wp\/v2\/posts\/112\/revisions\/116"}],"wp:attachment":[{"href":"https:\/\/blog.mykos.org\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=112"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/blog.mykos.org\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=112"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/blog.mykos.org\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=112"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}