Replies

1. 
   user-180107 | Jul 19, 2006 07:48am | #1

   You can make a jig to make any size oval that you want. Create a baseplate with perpindicular grooves (a cross) using a dovetail bit. Cut & route 2 short (1" ) pieces of timber that will be able to slide in the baseplate grooves. Put a pin/nail into these. Then create a trammel that will suit the baseplate of your router. Put a series of holes (to suit the pins) on the trammel.

   You can now use the trammel on the base plate to create ovals. Adjust the 2 points to determine the height and width of the oval you are going to make. Just need to take care as one of the pins crosses the crossing point of the two grooves. I did find a plan in a routing book (can't remember the title) I used this with a 45 degree chamfer bit to create a oval in ply for a mantel mirror. Looks a million dollars.

1. 
   mapleman | Jul 19, 2006 08:23am | #2

   Hi,

   I have a porter cable 690 router. I don't believe the size of the router would allow making the 10" part of the oval, with the width of the base plate of the router, and the base plate of the jig. This idea would work with a large oval.  Thanks, though.

   Lee

   Edited 7/19/2006 1:25 am by mapleman

2. 
   RickL | Jul 19, 2006 02:28pm | #3

   Why can't you use the folded paper technique or string method and make your own template? 

   Any shop with cnc equipment would surely have template material on hand. You could try your local yellow pages for commercial shops. Topics to search for would be sign making, machine shops...lots of shops have laser for metal fabrication.

    

1. 
   mapleman | Jul 19, 2006 05:48pm | #4

   Hi Rick,

   I'm not real comfortable with either method you suggested because I'v never done them before. The smaller oval will be routed on the top of the base, and then the larger oval will be a rabbeted ledge on the back, which a piece of 1/4" plywood will fit into, but it needs to be a perfect fit. One of the customer's complaints is that the person who was making these for him previously did a horrible job fitting the backs on (looks like a rabid beaver cut them). I'm just striving for perfection, and not real sure how to draw the ovals. I also fear having to spend hours sanding the inside of the template to smooth out my not-so-great jigsaw skills. I make jigs all the time, and enjoy making them, I'm just not looking forward to doing this one.

   Lee

1. 
   RickL | Jul 19, 2006 06:10pm | #5

   http://woodcraft.com/family.aspx?familyid=3056

   It's really not that complicated to do that project. You said large numbers of ovals and backs. Why not job it out to a cnc router or laser.  You can buy a Shop-bot or similar type of machine for a reasonable amount of money. Go to the prosite http://www.woodweb.com and talk the cnc forum or just pull out the  Wood and WoodProducts Redbook and look up cnc firms  and folks who make component parts.

3. 
   bldrbill | Jul 19, 2006 06:44pm | #6

   You can lay out any size oval you need with a framing square and a couple of nails for pivot points.  I haven't done this in awhile, so I'd have to look up exactly how to do it.  I'll send you the info if you need it, or someone else here will surely know.  Or you can buy one of the #### grinders from Woodcraft.