Previous posts:
- part 1: Design tool
- part 2: Mold
- part 3: Glue-up
The board came out of the mold without issue, and it looked majestic! Over the following days, the form did bend back slightly, so next time I’ll exaggerate the specs even more in order to end up with the exact shape I want.
I used the CNC to cut out the profile of the board, but that wasn’t my brightest idea it turns out. Next time I’ll just use a jigsaw with a template.
To fillet the edges, there exists a tool that you can put in a router table, but it costs quite a bit so I tried making my own version.
I glued some HDPE scraps (from the cat doorway project) together and quickly made this piece. It uses the existing mounting holes so I know it’s always going to be dead-center to the router bit. It turns out it works, but its profile is not high enough to reach every nook and cranny around the profile of the board. That’s as long as my shank is unfortunately, so I finished the rest with an orbital sander.
I sanded all the surfaces one last time and called it a day. Looking good already, but I’m going to put graphics on it in a next post.
