Made this for a local American Legion post. The center part of this is a 9" dia. circle cut from 1/2" beech wood and the lettering is approx. 3/4". The scroll saw part was a breeze. Now the challenge.
Each ring has a meaning within the logo and all needed to be in place. I set up my router table with a series of holes and using a pin I turned the wood over an 1/8" veining bit 3/16" deep. I also used this process to finish cut the outside dia. of the circle. I actually did this before I did any scroll sawing.
The ultimate challenge came when I realized that to make the starburst I had to cut each piece, 120 total, at a 3* angle. The shortest piece is 3/8" tall by 5/16" wide & 1/4" thick and the tallest 1.5 x 5/8". The pieces are too small to see the angle and it would be a glue up nightmare. After heavy thought this idea was scraped.
To make the starburst I glued strips of cherry and oak each progressively wider, 4.75" finish by 4' long. I then crosscut those strips to 3" long to allow for waste. I cut 10 pieces with an 18* angle on each side which gave me my 360* circle. I glued the ring to some 1/8 plywood that I painted black. I cut the points,120, with a 5* draft so they wouldn't look so flat. Opps the table only tilts to the right, turn the blade towards the back of the saw and cut the other side.
I then went back to the router table and cut the inside dia. of the strips to allow the beech wood circle to set flat on the plywood backing, piston & shaft. This allowed the center to protrude 1/4" and gave me something to glue the centers of the "r,o,a". Install brass brads and polyurethane.
My ultimate challenge and most rewarding.