SteveNelson46 wrote:Nice job, Ted. The only thing crazy about it is that it probably took a lot of work.
Yes and no. The hardest part was deciding what I wanted to do. At first I was going to use 3D models. But I did not like that. So the chip carving look came to mind and then it took a while for some inspiration. Wayne Barton's stuff got me going in the direction I liked. Then it was a matter of drawing up the shapes, sort of fussy work. I use Corel so the Smart Fill tool makes it easy to get closed shapes from lines that cross over each other.
The trickiest part was providing for the cut line to remove the top from the bottom. It is not possible to just split them, pull them apart and then draw small connector lines. That does not work with curved lines at all. So the trick was to create a copy of the design split the top half using the lower edge of the cut line and vice versa for the bottom half. Then moving them apart the width of the cut line and welding it all together. Worked out perfectly. Figuring THAT out took a while.
Also needed to build a fixture to do the hinge pockets. The way I did that was to secure a tall rail on the machine then machine it to a specific width. Clamp the top and bottom halves to it and then layout the mortises for the hinges accounting for the thickness of the rail.
The sides/front were pretty easy. I use vises on the machine. The vises have sacrificial jaws so I milled a step into them which gave me a perfectly straight surface and a reference for the back of the pieces to ensure they were flat to the machine without having to surface them.
The finger joints were a bit testy. That had to do with the bit size being a bit off and my not laying it out so that adjusting the bit size would not screw things up.
All in all I spent the vast majority of my time getting the design where I wanted it. The actual machining went smoothly all things considered.