Looking for Ideas

[oldhudson]

I took a job to replace a combination molding/glass stop in a really old oak door. The door has a large etched glass ellipse in the center, 51 x 19.

I made a paper pattern (1/4 of the ellipse) by holding a large sheet of brown packing paper and forcing a crease into the stock by pushing it to the point where the glass meets the molding, on the good side of the door with undamaged molding. I cut the paper as close as I could to the crease. I then traced the pattern onto a piece of 5/8" x 1 1/4" pw. I cut this out on the band saw and sanded to the line.

I plans to affix the template to the replacement oak stock with double sided tape, rough cut on the band saw and clean up by flush cutting with a router. I can the cut the profile in the stock with a router bit guided by a bearing.

The issue is that looking at the template and running my fingers down it, it's not smooth. Between making the paper pattern, tracing it onto the pw, my shaky hands and cutting it out - it's not smooth - there are high and low spots along the 28" of stock. I could post a pic but I don't think it will capture the gently roller coaster I own. Of course I've tried sanding. I keep knocking down the high points but can't seem to match the valleys.

So if any of you folks have a suggestion or thought - I promise to be eternally grateful. Thanks for reading.

[amazingkevin]

Wish i could help ,

[Birchbark]

Use a compass, the kind you use to make a circle.  Make the opening exactly 1" or whatever.  Then run the pointer end against the paper, with the paper roughly against the stop.  Then use that as the pattern on a piece of 1/4"  Leave the line as much as possible.  Just sand etc. up to the line.  Next put the 1/4" under the full size piece that you are going to use, and run the router bit against the 1/4" template to have the finished piece of wood.  I hope you can understand all that.  lol.  I know what i mean!!    any questions let me know and maybe i can make it clearer.  idk.  Good luck tho either way.

 

Russell

[LarryEA]

molding jigs, crown molding tool,

Crown molding tool.

I think there are tools that you press against a molding and it follows the contour. Would one of these help?

They may come in various sizes.

[spirithorse]

Hi, Berry,

If the glass you are working with is a true ellipse, you can draw a perfect ellipse using a system like this

http://www.finewoodworking.com/workshop/tip/a-precise-method-for-drawing-an-ellipse.aspx

 

or, you can draw an ellipse to the measurements you want in some of the graphics editing software.

I don't know what program you use but, there is probably a youtube video on that process if you look up your

program.

 

Maybe rather than trying to crease the paper, you could use chalk or lipstick on the good casing and press

poster board against it to give you the exact shape you are looking for.

 

Good luck and God Bless! Spirithorse

[LarryEA]

There's a Better Way: Drawing an Ellipse-ish - Fine Homebuilding

www.finehomebuilding.com/.../theres-a-better-way-drawing-an-ell... - Similar

to There's a Better Way: Drawing an Ellipse-ish - Fine Homebuilding

May 7, 2009 ... Build a jig to draw a perfect ellipse

[LarryEA]

OOPS

Edited April 16, 2015 by LarryEA

[oldhudson]

Well I think I have the sanding - smoothing sorted. I'll work on it today and cut a test piece from pine today or tomorrow.

 

I made a flexible sander from a very thin piece of stock, added a couple of handles on one side and sand paper to the other with carpet (double sided) tape. They bend nicely and sanding knocks off the high points without cutting into the valleys.

 

I think the pics with explain this. In the pic with the clamps I just using the clamps to demonstrate how the tool conforms to the curve. I made a longer and a shorter one. The shorter is for the tighter radius portion of the curve.

 

[Birchbark]

Very innovative!!!  Like it.  Lots of work. 

 

Russell

[grosa]

This is the type of jig I use to rout or draw an ellipse. It is very easy to make and you can mount a router to cut it out or a pencil to draw it. Tip: the tighter your tolerances the smoother your cut. You can make it out of any type of wood or mdf. Hope this helps

 

Edited April 19, 2015 by grosa