I made sawdust!

[KA]

Hi,
I finally used the jig saw and cut out my side profile pattern (pix in album) today...phew. I still have all my fingers. I sanded the edges as smooth as I could get them. Friends donated a nice piece of 1/4 plywood for my pattern (they want me to hurry up). I used a slightly modified Benroy pattern that I purchased from Grant. . My cuts are a little wobbly in places, but I hope to use the router or my friend's band saw to cut the actual sides. I figure that I will use this profile a lot in my build...as a pattern and also to try out some different finish techniques. Eventually the piece of wood could wind up as part of my cabinets.
The hardest part for me was cutting out the door hole and I could use some advice for next time. I drilled holes in the corners and put the saw in the holes to start my cuts. I was wondering if there is a cleaner way to do this so that the remaining door piece will be useable in the build.
Thanks for any advice.
Kris
p.s. If you get a chance to go to LeMay next year, do so. I have never seen so many amazing cars in my life....Of course the teardrops were way cool, too.

[madjack]

...so, no longer a virgin, ehh...so how was your first time(makin' sawdust) ...........................

[Miriam C.]

First time is always the toughest. Use a belt sander on those wobbly places. Smooth them right out. Can't tell you a easier way cause that is the way I did mine. (no pattern)

Looks great

[Micro469]

Kris, when I cut out my doors I used a jigsaw. Just started it and angled the blade into the wood until it cut through. Gotta be carefull tho, because the blade tends to jump all over the place if it catche. Do it on the backside, and maybe practice on some scrap first.

[doug hodder]

Another trick that I've used, is to mask off the area where the blade is going to be cutting and put your lines on the tape...helps reduce tear out from the blade...and for drilling a hole to start...don't do a big one...a small bit with a series of holes in line will work also...less waste and the door panel is usable....Doug

[mikeschn]

The hardest part for me was cutting out the door hole and I could use some advice for next time. I drilled holes in the corners and put the saw in the holes to start my cuts. I was wondering if there is a cleaner way to do this so that the remaining door piece will be useable in the build.

Kris,

What I do is drop a circular saw into the line near the corner, and then cut to the other corner. I repeat this process for the other 3 sides, and then cut the corners with a jig saw.

This is not something you want to try for the first time on your side wall. Play with a piece of scrap first, and make sure you have your saw under control. Things like trying to pull your saw rearward or changing the angle will destroy your wood, and scare the sh*t out out of you too.

For the doors I also clamped down a board to use as a straight edge.

Mike...

P.S. You can also feed a jigsaw into the wood without holes, but practice that so you know what kind of results you are going to get.

[KA]

Hi Doug, Madjack, Mike, Miriam, and John,
Thanks for the great ideas. I'll definitely be braver on my next adventure with the saw, but will keep your flying-blade cautions in mind. I definitely need to keep all of my fingers for when I get to the dutch oven section of this forum.
Kris

[madjack]

Kris, I use the technique Mike described regularly but would consider it an advanced technique, not suitable for beginners...also keep in mind that the door...after cutting out with a saber saw will still have to be cutdown another 1/8th to 3/16th of an inch all the way around it's perimeter for proper clearance of the trim etc.
madjack

[KA]

Thanks for the tips, Madjack. I didn't realize you had to trim the door down...makes sense in order to accomodate the trim. I would have had to learn that one the hard way.

As far as cutting techniques....I'm going to attempt the ones that scare me the least and work ever so slowly up from there.
Kris

[tonyj]

I would also suggest reading up on using a router and templates.

Make the template of your door opening out of 1/8 or quarter plywood (my preference). Spend time to make all the curves (and straight lines) perfect and smooth. Any error here will transfer to both the side and door. Mount the template at the appropriate spot on the side. Drill a starting hole slightly larger than your router bit. Use a straight (or preferably spiral cutting bit) with a collar that matches your bit on your router. Place router in the hole, turn it on and follow the outline of the template. Using a 1/4 inch bit (5/16 if you can find one), gives you an almost perfectly cut door and matching opening with very little additional sizing required. Use a jig saw to square up the square corners.

I used a jig saw, and circular saw, and sander, and mini planer, and sanded and sanded and sanded. And the door and opening still weren't right. I made a template and used the router to clean up the opening and door, and now I can sleep at night.

I know this is probably considered a more advanced technique, but it is well worth the time to master and a lot easier than it sounds. The time is spent on making the template. It is also a very safe way to make the cut. Mike is right--a circular saw can do some very surprising moves when making a plunge cut.

[KA]

Hi Tony,
That sounds like great advice. Thanks also for the bit size recommendation. I need to make friends with my new router (I know how to plug it in and which end is up) and the door template sounds like a good place to practice.
I love hearing about the different ways people approach building their tears, especially when the instructions are broken down into steps (relatively new woodworker here).
I appreciate everyone on this forum for taking the time to offer advice. There is no way I could build my trailer without this help.
Kris

[madjack]

template guide set
Kris, to make full use of your new router with its plunge base you need a bushing set similar to the one linked above(should be available locally)...the bushings attach to the router base allowing it to follow the template...using the basic instructions that Tony provided you can set the router on the template with the bushing against the edge of the template...starting the router, you then "plunge' the router into the work piece and follow the template to make a perfect door and openning with the proper gap...yes this is a relatively advanced technique and you should find a router book and read up onit and follow that up with some practice and you will master it in no time...
madjack

[KA]

Thanks Madjack,
I'll take your suggestions and practice with my router. Thanks.
Kris

[AmyH]

Kris, congrats on making your first batch of sawdust!! The profile looks great! I made a bunch of sawdust this weekend myself. I have been working on the decorative inlays for the sides. Running the wood through the jointer and planer made a TON of sawdust!! I should have plenty to put in the compost bin now!

I am planning to use the router method that Tony and MJ mentioned for cutting out the sides and the doors. If I get to it before you I'll let you know how it goes. Of course if you get to it before me, let me know how it went for you,

Amy

[KA]

Hi Amy,
I bet those inlays are going to look amazing...can't wait to see how they turn out.
Kris