(01-18-2021, 08:29 PM)WxMan Wrote: Rob...looks great! I'd love to see how you laid that out.
Measured the major and minor diameters of the stained glass. Add a little bit because it has some variation, being hand formed lead (I forget the real name of the H channel lead stuff).
Took those numbers to Fusion 360 (CAD) and finished drawing my oval, expanded for width, accounted for the rabbet, etc.
Export that information to an SVG (standard vector graphic) file and used my Shaper Origin CNC to make a template from 1/4" MDF.
Back to Fusion 360 and fiddled around to get the angles on the ends of 6 pieces of wood. Why 6? Well, as part of the fiddling I was trying to make sure I could use up cherry of about 5" and 6" wide left over from several projects. Then cut the blanks. Spent a little time fiddling and tuning the angles with a shooting board until it all came together reasonably well.
Off to the router table to use a slotting bit to cut for splines. Little time to make the splines and fit them. Little more time to wrestle it all together with glue, strap clamp and a pile of C-clamps to make sure the splines were clamped too.
Traced on the oval and removed the bulk with a jigsaw, following up with a bearing guided compression bit back at the router table. The template was tacked on the back side with a few small nails.
Cut the rabbet with a trim router and spent a bit of time with a card scraper to finesse the fit since the stained glass isn't a perfect oval. There were a few places that needed a little bit of filler, the nail holes for example. Sand it up to 180 followed by a wipe down with water to pre-raise the grain and another sanding.
When I'm done with the sealer coats I'll take a picture that shows an example of the spline.
Don't sweat the petty things and don't pet the sweaty things. -- G. Carlin
