Looking for Ideas

[berry]

I took a job to replace a combination molding/glass stop in a really old oak door. The door has a large etched glass ellipse in the center, 51 x 19.

I made a paper pattern (1/4 of the ellipse) by holding a large sheet of brown packing paper and forcing a crease into the stock by pushing it to the point where the glass meets the molding, on the good side of the door with undamaged molding. I cut the paper as close as I could to the crease. I then traced the pattern onto a piece of 5/8" x 1 1/4" pw. I cut this out on the band saw and sanded to the line.

I plans to affix the template to the replacement oak stock with double sided tape, rough cut on the band saw and clean up by flush cutting with a router. I can the cut the profile in the stock with a router bit guided by a bearing.

The issue is that looking at the template and running my fingers down it, it's not smooth. Between making the paper pattern, tracing it onto the pw, my shaky hands and cutting it out - it's not smooth - there are high and low spots along the 28" of stock. I could post a pic but I don't think it will capture the gently roller coaster I own. Of course I've tried sanding. I keep knocking down the high points but can't seem to match the valleys.

So if any of you folks have a suggestion or thought - I promise to be eternally grateful. Thanks for reading.

[charlese]

Ahh! Now you are into the art of FITTING!!!!

Hope you have sawn on the outside edge of your paper template. Sounds like you may have to try several fittings. It's often best to make your first piece of wood (or hardboard) on a throw away piece - mark the areas that don't fit and trim the high spots and mark the low spots. You can trace the improved template on another piece of hardboard and try again. You might have to do this operation more than once.

[berry]

I think I have the sanding - smoothing sorted out. From somewhere in the depths of memory I remembered this idea. (I think it came from Woodsmith or ShopNotes.)

I made these flexible sanders. A very thin piece of stock, one which can conform to the general shape of the curve, a couple of handles on one side and sand paper on the working side. Here are 3 pics. I the one I have clamps holding the sander in position to demonstrate how it conforms to the curve. The shorter tool is for the tighter radius of course.

flexsander123.jpg (68.36 KiB) Viewed 2221 times

flexsander124.jpg (69.04 KiB) Viewed 2221 times

flexsander125.jpg (67.5 KiB) Viewed 2221 times

[benush26]

Not exactly a solution but more of a "you might want to try this next time" idea.

There is software called BigPrint by Mathias

http://woodgears.ca/bigprint/

I see the cost has gone up to $22, however I think I paid less?

It allows you to take a picture of what you want to copy, then scale it very precisely and then make a full size print out. We used it for a couple arched windows and curved casement in a 1890s house. Worked very slick and saved a lot of extra words which would have come with the extra shaping using the brown paper hold it in place and sketch method.

Just a thought for next time.

Be well,
Ben

[drl]

Berry is describing exactly what The Wood Whisperer taped recently. Here is the link:

https://www.youtube.com/watch?v=Ebbp4TIQWV8

Regards,
Dwight