Even though this is not a CNC related question, I value the wisdom of the traditional woodworkers that frequent this forum, so here goes:
I have been asked to bid on a project for a customer to make three 57 3/4" square frames that will be added to a hallway with many more identical frames. They reached out to all the local frame shops and were told that this style has been discontinued by everyone so they are seeking a place to have them custom created. The sent a couple of photos that are not great so I went to the facility with calipers in hand and took a few measurements.
They are looking to have these in mahogany which I think I actually have enough of on hand. The big question is whether I can create the curved profile.
I think if I can create the curve then the rest is pretty easy and I need to cut a rabbet on the back for a plywood backer to be fastened in there.
The only idea I have so far is using one of these bits in the router table: Fingernail / Convex Edge Router bit-0604 – FindBuyTool.
They come in 2" and 2.5" but not 2.25". Even with the others, the radius they claim looks to be too small.
I have Vectric Vcarve and have been playing with the molding toolpath for another project but it would take about 17 years to cut the pieces for this one using that technology.
I have access to a shaper but haven’t found any shaper bits that would work either.
I had to do something similar years ago. Probably not the best way, but it was pretty simple, though tedious, to run it through the table saw. Basically
Print the profile and glue it to the end of your stock.
Line the blade up with the drawing and run it through. (Easier if symmetrical because you can flip the board and do two passes per fence/blade move)
For the convex curve, take tiny moves with the fence and blade height.
A custom shaper bit or find someone with a molding machine and have the inserts made. Either way it is going to cost you some bucks to get either one made. The expense of the cutters and or having someone with a molding machine cut these may put the customers cost in the 200 to 300 dollar or even higher range for each.
Custom shaper heads can be made for 300 to 500 hundred dollars and can take 4 to 8 weeks.
You could try reaching out to the original company and see if they are still in business and if they have the original cutter. May be a long shot but they may even be able to cut some for you if the quantity is higher.
https://mouldingknives.com/ has some standard shaper knives
I did see one that looked like the curve part at least.
I would dig around the shaper knife suppliers, if that was a former standard profile, it might be available.
My calculation was about 60+ ft of frame stock. So it is a bit much.
The other option is to check the architectural millwork shops around where you are,and see if that have that profile available.
Yeah, I can model it in Vcarve Pro but based on my earlier test with the molding path it would just take too long and having to tile it would be risky for something like that.
I struck up a relationship with a local millwork place a few months ago. I will reach out to them. I really wish I had a piece of the current frame rather than relying on my measurements. The customer is about an hour away and it’s on an Army base so access is kinda limited.
But doing 60ft, 1/4" at a time…3,000 passes. EDIT: Makes more sense to run it the length of the board…duh.
That’s a cool jig. You could use the Shapeoko to cut one out if you don’t have a printer.
It reminds me…I’ve used 3D printed sanding blocks for specific radii. You could do that once you’re close.
The local millwork shop gave me a price of about 1k which includes ordering a custom knife, setup, wood, and running it. The customer wasn’t scared by that price and it will certainly reduce my stress level.
While they do that I can figure out how to make a 52” square back plane for the frame to sit around.
Maybe use the CNC to make interlocking cuts to provide more surface area for glue.
There are plywoods available in five foot wide pieces
Baltic birch was generally available in 5x5 form factors. (Availability has been affected by geopolitics)
I am pretty sure 5x8. And 5x10 are available from some plywood suppliers
5x5 would be perfect. I will see if so can find a local plywood supplier that would carry it but I am somewhat dubious of that prospect. Maybe in Jacksonville which is a 2 hour drive.
John,
Baltic Birch is never AA, always AB at best. Recommend ApplePly (used it, excellent stock, unfortunately 1" oak not available any more) or EuroPly (yet to try). A local hardwood store carries Mahoganny Plywood: really good stuff for boats, Hacker Craft uses that, says a lot. Little brittle for CNC work, and not really cheap…
Any ideas what good thin layered plywood to get from somewhere?
