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 0239.JPG - With router attached and all mating surfaces sprayed with lacquer and waxed. It slides very well back and forth.
Thumbnail for IMG 0233.JPG - The first test fit of the jig with one edge guide attached.
Thumbnail for IMG 0225.JPG - The top parts of this will be the carriage for the router and the bottom are the rails.
Thumbnail for IMG 0231.JPG - Layout of the pieces on ¾" MDF. I bought the ¾" and 1⅛" MDF from a local lumber yard and not one of the "big box" stores. I don't think the MDF from the "big box" stores is of very good quality.
Thumbnail for IMG 0257.JPG - The last ½" still to cut.
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Thumbnail for IMG 0250.JPG - It produced a beautiful 9 ft. radius curve. The material is 1⅛" MDF. I removed about 1mm from the apex and that left a ¾" edge.
Thumbnail for IMG 0245.JPG - As the router is slid back and forth, the side being cut will be pushed under the router. I used the top half of some cam clamps to act as hold-downs to the side piece.
Thumbnail for When you drive the â…›" pin into the center of the circle and scrap backing, it acts like a nail and compresses the cushy liner material and prevents anything from moving. And yes, that is a Black & Decker 7620 router that dates back to 1975.
Thumbnail for My technique for cutting the circles out of the braces is to use a Jasper Circle Cutting Jig and a piece of non-slip liner. This is the stuff you use to put under a rug to keep it from moving and it's also sold as shelve and drawer liner.
Thumbnail for In the router table is a Bosch Flush Trim Bit, ½" x 1", triple flute Carbide tipped.
Thumbnail for I used a template to cut the internal braces to make sure that each one is exactly the same size and shape.
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