Making template's: scroll saw?

[PoconoJohn]

I experimented with a 1/8" blade on the band saw and found I wouldn't be able to make nose template's...even with the guide practically on the wood, the blade wiggles just enough that I can't make a straight/even cut plus I can't see the line. Next I experimented with a drum sanding bit on the drill press, and that results in slight bumps; and the paper doesn't get removed with the wood, so I can't tell if I'm down to the line or not. It seems I may need to use a scroll saw but before I spend more money on another tool that'll take up space, just wondering what worked for you. Thank you in advance.

[dougm]

Hi John,
Are you talking about only the templates or all of the ribs? For the template I used my band saw and a sander and took my time.

[PoconoJohn]

I'm working on the nose blocks. I used the band saw to cut close to the lines. I then tried using the drum sander to finish it off to the line, but I can feel slight bumps. I want a even surface. I'm not happy with it. The big bump is where I stopped. The third photo shows how the paper doesn't come off so I can't tell if I'm at the line or not. I'm thinking a scroll saw is the better way to make these.

[jwhanson]

Hi John,
I would suggest making an aluminum template and trace your parts on plywood, so they are all the same. Then cut them close on a band saw and finish them to the line with a belt sander, or a sanding disk on a table or radial arm saw. It is much easier to control than a drum sander. We did not use any paper for templates because the paper stretches and shrinks with changes in humidity.
John Hanson HC-012

[dougm]

I did use a scroll saw in the tight spots, now that I think about it. Once I had a good template I rough cut all the nose pieces and attached the template to them one at a time and cut them all on a router. See the link:
http://www.damowry.com/hatz/thumbnails.php?album=2
or
http://www.damowry.com/hatz/thumbnails. ... m=4&page=2

[Al Hatz]

John,

Use a 1/4 blade on your bandsaw for cutting then use a belt or disk sander to finish. You don't need a scroll saw, unless you really want one.

Al

[wassbiplane]

Did no one use a master template as a guide for a router bit with a ball bearing nose piece--??--lotta discussion on the early Kelly D site..Don't think I have any digital pix of the set up---it was 35mm film when I made mine. still got my jigs tho.

Could take some new pix if there's enough interest--'course if you wanna go to a KD airfoil you could borrow my jigs.
jerry

[dougm]

Did no one use a master template as a guide for a router bit ...
jerry

That's exactly what I did, but I thought this was about making the template itself?

[PoconoJohn]

I ended up buying and using a scroll saw to make templates. Working slowly, I cut close enough to the line so a little 'white' showed. I then placed it in the jig to see how it was lining up. I used the scroll saw and band saw to work away the leading edge notch. I initially used the disc sander to get closer to the line if I needed, but eventually I put the nose rib template in a vise and sanded it by hand. I was constantly going from jig to vise (for sanding) until it was as perfect as I could get it. In the end, it took six attempts. The scroll saw came in handy for the interior of the false rib template. I have large photos of my progress here (you can leave comments at individual photos or at the photo album): http://imageevent.com/hatz

[tlandrum]

Hi John,
I would suggest making an aluminum template and trace your parts on plywood, ....
John Hanson HC-012

How did you make the aluminum template? There is a professional CNC shop who could do the work... did you just take them your blueprints and have them digitize them... or is there a set of digital prints somewhere? I will likely do most of the metal hardware with a CNC machine, so they will be needed for that too.

Tre'