6. Back on Track Making Frames
Well, I think the little setback is the best thing that could have happened to me. I'm back on track now and have a little over half the frames built and they look a heck of alot better than the first ones. Restarting was definitely the best way to go.
So I thought I'd break down how I've been building my frames. It's alot like some of the other ways I've seen, but with a few little twists. It's been changing a little bit with each frame since I've found little ways to
make it more efficient. but here's where I'm at now.
1 - cut out pattern pieces for frames
Pretty self explanatory here- just make sure there is extra "meat" one all four sides of the edges. I probably leave at least 4 mm just so I can get a good adhesion for cutting.
2- apply the pattern to the wood
For this I used 3M Spray Mount. I have mixed feelings about this product since sometimes it peels off in the middle of cutting and other times it takes forever to try and remove it all from the wood. I can't find any correlation between dry time, cleanliness of wood, or the amount of spray- so after this project I'll probably be looking for something else. If anyone has any suggestions I'm open to them.
But back on track- Because of the shapes of the floors and futtocks, it's pretty easy to conserve wood and tack everything to the wood close to each other. I tried to avoid doing that since thats what led to my demise the first time around. Maybe when I get better at scroll sawing I'll feel more comfortable cramming everything together, but for now I've given each piece some air to breathe. I tried to stay with the grain but was not horribly worried about it on this model. It seems like that becomes very important with cant frames on full models. One last note on the 3M Spray Mount- it gets everywhere. I'm using a pair of needlenose pliers to hold the pattern while I spray it so it doesn't cover my hands. I've also since learned that spraying over the garage floor will cause the wife to ask questions like "Why is the floor all sticky?" - so I do all my spraying over the garbage can now.
3 - cut out the pattern
I gave myself about a 1mm cushion on the sides and about 5 mm cushion on the heels of every piece. I think if there's ANYTHING taken away from this post- this is it. It's save you lots of future trouble and money.
4- file out the floor where it will sit on the keel.
I just used a couple small square files I got at the hobby shop for this. Took off a little at a time until the floor fit snugly on the keel.
5- Assembling the first side of the frame.
Once I knew the floor would fit on the keel, I sanded down the heels right to the edge of the line. For this I used a disc sander which has made things go really quick. It's important to make sure the table is squared up to the sanding disc to avoid problems later. Then I taped the floor down in position on the assembly drawing- which you won't see in the photos since that was something I just started doing last night. Everything else gets based off the floor, so it helps having to recenter it all the time.
Next up comes the second futtock. I sanded down the heel where it'll join the floor right to the edge of the line, then checked the fit. The goal was to have the heels sit flush AND have the frame eventually fit naturally into the jig without any pressure. Most of the time the futtocks will have to be resanded by just "touching" them to the sanded to get the correct angle. This was what I shot for..
After it "looked" good, I peeled back the edges of the pattern to see make sure the heels were fully flush..
Once everything looked kosher, I glued the floor and second futtock together. I found that poking the heel with an exacto to leave some small divits for the glue seems to give a better joint..
From here I just repeated the same steps to apply the fourth futtock, which gave me the first side of the frame.
6- assembling the other side of the frame
One half the frame is done, the rest was pretty easy. I started by peeling the pattern off of the floor and second futtock, but I guess there's no reason not to take all the patterns off. It's important to watch for residue from the pattern or glue that could prevent both sides of the frame from sitting flush and leaving gaps. This is a little extreme, but a razor will scrape it all off..
Now I was ready to line up the first futtocks. The hardest part was having both heels sit together and still line up with the floor and second futtock. But once I got that, I just sanded the heel for the third futtock and got ready for glueing. I did the same thing with the divits on the heels and also on the face that was being glued down. Then just a little glue and a bunch of colorful clamps..
Once this was done, the rest is just repeating what was done above. Making sure the heels are flush and everything lines up with the assembly sheet in the plans are the biggest points. I sanded down a couple of the first frames (but have since left all frames unsanded so I can do all them at the same time) and have found that the joints are so good I had a tough time finding them. Two of my friends have taken a look and thought each frame was made from a single piece of wood! This is the finished result..
- file out the rest of the seat for the keel
Since the floor is correctly filed for the keel, I just had to match up the first futtocks. Here's the right side done and the left side ready to be filed..
...So that's it so far. I have to make a few more frames before moving on and may remake a frame or two also. I tried out some treenails on one and found that the Dremel workstation does not take the place of a good drill press, so that may be my next investment. I know this was a pretty long and detailed writeup on making frames, but this was one thing that I had no idea how to approach coming into this build, and like I said in the beginning- hopefully this will help someone else in the same boat as me. Oh yeah- here's how it's looking so far
After the frames are done, I'll be working on sanding them down and treenailing.
Edited by ChadB, 24 December 2016 - 05:27 PM.