Teardrops n Tiny Travel Trailers

I am approaching the point in my build where I will be cutting the completed exterior walls to make the templates for the galley hatch ribs. I have found that my scroll saw does not cut perfectly up/down sometimes when I am cutting thicker stock - the blade drifts just a bit and I get an angled cut. I am obviously wanting my cuts on this very important step to be as near perfect as I can make them.

My question is what tool to used to make the master rib - that will ensure the best cut.

Poorlytiedfly wrote:My question is what tool to used to make the master rib - that will ensure the best cut.

I used 1/4" MDF to make a template. The template was cut by a jig saw just "shy" of the line. Then I sanded down to the line for the final profile.

I made my router template out of 1/4 inch luan; easy to cut and shape but only just thick enough for a guide roller to follow.

I made the rough cuts on a small vertical band saw, but a hand held jig saw would have worked, too. Even just scoring several times thru with a utility knife would have worked (if that were my only option). Then I sanded to the line on a small bench top combo disc/belt sander, at least for the outside curve and ends. A hand held belt sander would also work if you clamped the piece up in a vise. On the inside radius, what I couldn't get with the bench sander, I hand worked with a small wood block and sandpaper.

If your ribs will be exposed the trick is to make sure you don't have any nicks or rough spots in the template. Go over every surface with your finger tips and sight along all of the curves to be sure you have nice smooth transitions and no flaws. Any flaws will be found by the router bearing and will be telegraphed thru each part.