OB-5 Construction by Carlos / http://www.audiocircle.com/circles/index.php?topic=59326.0

OB-5 Construction by Carlos See thread at: http://www.audiocircle.com/circles/index.php?topic=59326.0
Thumbnail for IMG 0221.JPG - The cut had to be perfect at 90 degrees. Each pass would cut about â…›" (2mm) off.
Thumbnail for IMG 0229.JPG - The cutting bit is a BOSCH micro solid carbide, upcut, end mill. ¼" cut ¼" shank, 2½" OAL.
Thumbnail for IMG_0220 - The first task was to accurately cut the bottom rail and top carriage runners at a 9'1.77" radius. This required a lot of preparation.
Thumbnail for OB-5 JIG-SIDE-Layout 1 - Side view of curved-side cutting jig. This will make a 9' radius cut.
Thumbnail for OB-5 JIG-FRONT-Layout 1 - I drew this up using AutoCad 2004 so I could get a good idea of what was needed and the dimensions necessary to make things fit.
Thumbnail for IMG 0226.JPG - Here is one side of the guide rails cut. I've embedded two ½" rectangular steel tubes into the bottom of the rails to help support the weight of the router.
Thumbnail for IMG 0224.JPG - The edge guide that came with the router made the perfect connection piece.
Thumbnail for IMG 0228.JPG - I used a ¼" aluminum pin to anchor it.
Thumbnail for IMG 0222.JPG - Here is the 9' extension to hold the router.
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Thumbnail for IMG 0244.JPG - This was a test layout of the jig setup on the table saw. I used the table saw because it has a perfectly flat surface to keep things all on the same plane.
Thumbnail for IMG 0237.JPG - The router is the venerable Hitachi M12V at 15A, 3¼HP. It will accept a ¼" or ½" shaft bit and weighs in at 12.4lbs. The bit is a Grizzly double fluted straight bit, ½" shank, 1¼" cutter diameter and 2⅝" OAL.
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