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Router mill assembly has begun

10/10/2013

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I have printed out the revised cut sheet and an assembly drawing to use for reference in cutting out parts.  I have selected photos that represent operations that might be unique to this build.  I'm not documenting the common operations like ripping ,etc.  The first photo shows a quick and "dirty" sled that accurately replicates parts.  Three nails in the waste plywood sled hold the position very accurately.  Interior openings were cut on my big scroll saw, but drilling holes in the corners and connecting them with a saber saw will work too.  The plunge feature of the Festool saw was handy for cutting the notches needed; quick clean and very accurate.  A hand saw finished up the cut and a little chisel plane action made the notch clean and precise.  Then I had to decide when to drill the hole for the pedal stop, and I chose to do it after assembly using my "vintage" Jennings bit.  It cut fast and clean in the test hole shown.  ( I deliberately got very close to the edges to see how much blowout.  None.)  Another way would be to use a drill press before assembly, but I thought it would be harder to line everything up.  So then I chamfered the bottom of the front feet with a little block plane and put the first seven pieces together.  Assembly has begun!  This part of the assembly I was fairly sure about, so I glued and pinned it before clamping.  I will countersink screws (maybe with plugs) later and use just screws for assemblies I'm not 100% sure about.
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    Dan is an experienced woodworker who is anxious to make an heirloom of the future for you.

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