"SAFE" staves for PMorley's cabinet
After last night's live Session, I was appalled by the reckless attitude in the chat towards the idea of using a table saw to cut the fluted staves for Philip Morley's record cabinet. This is unsafe and FYI, A SAWSTOP does not replace the need to use a brain. Anyway, attempting to offer a safe way to make the 8 fluted staves, here's how with Shaper Origin.
16
Cabinetry
Files Included (2)
Philip Morley fluted door stave (350mm x 62mm).svg
9 kBPhilip Morley fluted door stave maths.ods
17 kB
Materials
Wood as listed in Phillip Morley's instructiions
Tools
Shaper Origin
Workstation (or you could make a fixture)
1 x 8mm round nose router bit.
Instructions
My SVG is for a stave 57mm x 350mm, which is the metric equivalent of the Philip Morley spec. It has a bounding box 10mm longer (360mm) to give 5mm clearance either end of the stave when cutting. Therefore, position it accordingly with 5mm offset on X axis. Cut depths are all encoded . Start with the middle which is the deepest and narrowest, working down to full depth because that is the heftiest cut. Start cuts at the ends so the cutter descends before meeting wood. After each cut, change the path to GUIDE and SO's focus will move to the next cut path automatically. Set the depth and go for it. I have included a spreadsheet with the formulas for the depth of cut. If you change the values at the top, you can get curves of different dimensions. I thought that might be useful going forward. As you can see in the picture, the finish is easily as good as with any other power tool. a light touch with a card scraper would accomplish the minimal cleanup. Or you can use my cut depths to make a custom curved sanding block. Now there's a thought! You still need to trim the staves to final width and add that 0.6 degree angle for the coopering. This one stave took about twenty minutes but I wasn't rushing. 8 in hard wood would probably be 3 hours.