This morning I made another boardcut based on a free design from the forums. I decided to photograph each step in the hope that this might prove useful to new builders.
Special thanks to Mxred for his fantastic design.
Print out your chosen design and glue it to the piece of timber being used. A spray on adhesive can be used, here I have used a glue stick designed for paper. You don't want a strong glue as you need to remove the design later on.
Cut out your design with a saw. I have used a jigsaw here but you can easily achieve the same result using hand tools. A coping saw would be a great choice for anybody starting out.
Tidy up the frame. Most if not all saws will leave large cut marks or scratches on the work. Using files or a sander remove these marks and smooth out the frame.
Remove the pattern and sand some more. Make sure all lines are nice and crisp and you have your final shape for the frame.
Round and smooth the edges. Here I have used a router but the same result can be achieved with files and sandpaper.
(Note: I had the router speed too high for this and I have burnt the timber in places. This is not a problem with hand shaping and sanding)
Cut your grooves for securing the bands. Again I have used a router but this is just as easily done with hand tools. A round file works great.
Give everything a final sanding ensuring your forks are nice and smooth.
The frame is now ready for finishing.
The finished product after a good soak in Linseed Oil
Edited by Hrawk, 21 November 2011 - 09:16 PM.