Methods to utilize full size profile plans to cut

[cuyeda]

Or you can just use a CNC router

Show off! I am still trying to obtain a few more router bits for my new router. Besides, I don't have enough room in my garage for a CNC router. If one showed up in my driveway, I would surely make room for it! My next build... router table.

[So-Cal Teardrops]

Yeah, I'm spoiled. Although sometimes I find myself doing things on the cnc just because I have it. You have to learn that it's not always the best tool for the job.

Best tool in a teardroppers arsenal is a handheld laminate-trim router with some flush trim bearing bits. 1/4" hardboard templates are your friend and 1/2" "shear" flush trim bits (http://www.amanatool.com/bits-fv/47105.html) make quick work of aluminum.

Happy Building

[looped]

hmm a large wheel that wont destroy pattern paper and leave an imprint for carbon paper... goto the dollar store and get a pizza cutter, dull the blade with a sander.

just an idea

[2bits]

Well, I already cut out the pattern using the method in my previous post, but maybe others can use the other suggestions to help decide what works best for them.

Gabe, I will definitely look on to that shear flush trim bit!

Grant, thanks for the reminder on the door gaps! I decided to stop stressing over it, and I just cut it out with a jigsaw all around, it wasn't a big deal at all, and the profiles line up (including the doors) almost perfectly. I belt sanded them while they were clamped together, now they are exactly alike . I was just focusing on the fact that this was a $125 piece of plywood. Once I decided to do the job it was fine.

A couple of pointers for others:

I started the door cut using a trick my buddy showed me. Flip the jigsaw over and let it start the hole by gradually letting it dig through the wood. Then flip it over like normal to do the cuts. Practice this first. Yea it's not going to start on an exact line, but 1/4 of space was plenty to keep it between the lines.

On the first door, I cut the outer dimension first, then removed the door and cut the inner dimension off. I got a pretty good deal of laminate coming off this way when doing the inner cut. On the second door, I cut the inner and outer dimension one right after another on the each line one at a time, and I got no pull off at all.

I first cut the outer profile 1/8" "too" wide so I could belt sand the rest off. Don't waste your time. try to cut it right on the line and then the belt sanding will go much faster. I guess it depends on how good of a line you can make, I was worried but with a new fine too blade, I had plenty of control. I even blinked once or twice

Here's some pics

The first door


The second door


1 down!


Clamped up for belt sanding


Done! It was ALOT less stress doing it, than it was thinking about it.

[Miriam C.]

Great cuts. Thanks for sharing how you cut it and the pictures. Amazing how many people you will help down the road.