by KCStudly » Tue Feb 23, 2016 9:10 am
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.
KC
My Build:
The Poet Creek Express Hybrid Foamie
Poet Creek Or Bust
Engineering the TLAR way - "That Looks About Right"
TnTTT ORIGINAL 200A LANTERN CLUB = "The 200A Gang"Green Lantern Corpsmen