[For use if using a router in a router table to route edges of Bird Body's]
Important: Read the Warning before even considering making this
Warning: Using a router to
radius edges of small parts is neither a good practice or recommended. The
author makes no claims concerning the design or use of this guard. This
is a design for a guard that was made and used for making the bird patterns
shown on this web site. Use of a router without extreme care can cause
the router to shorten your fingers very quickly. This guard was made
after the need was made clear through actual experience. In other words,
the router took of the tip of a finger and it is not a fun experience!
Reading the warning above should be an introduction enough as to why this
fixture was designed. This fixture has worked well for radiusing the
edges of the bird body's shown on this web site. Making and using
this fixture is at your own risk. I personally recommend using
a soft wood, sand paper (lots of it) and plenty of elbow grease for radiusing,
however, there are people who like and use power tools. The intent
of this pattern is to provide an adequate warning of the dangers and offer
a possible solution (that has worked for the author) to finger amputations.
The concept is simple. When trying to route the bird bodies, I found
out that hard woods route fairly well, however, soft woods build up pitch
on the router bit and grab the piece. Grabbed pieces spin. Spinning
pieces are a safety hazard and can push a finger into the router bit.
Because most routers are spinning at 25,000 + revolutions per minute
(RPM's), it can make short work of a finger tip. Nothing like a trip
to an emergency room to make a fun project a dumb project.
The idea is to put 2 small holes through the body of the bird in an area
that will not be visible after the wings are attached. I use 2 small
wood screws that have enough clearance that the heads don't hit when both
are screwed into the body.
Because working with a router on a table with small pieces is tricky, mounting
the body to a clear lexan sheet allows one to route out the edges and keep
the fingers well out of the reach of the bit. It also allows one to
see the piece as it is being routed, provided your router has a light and/or
the bulb is not burnt out.
This fixture is made from a 6 inch by 8 inch by 1/8 inch thick piece of
polycarbonate plastic. I recommend POLYCARBONATE. The trade name
is Lexan, though there are other companies besides DuPont making the material.
I also used 4 pieces of 3/4 inch square by 6 inches long pieces of
wood near placed about 1/4 inch in from the ends. I also used 4 wood
screws to attach to the sheet. Substituting any other plastic could
be a big mistake. polycarbonate is also called burglar proof glass.
This material can take a hit on the router bit and only end up with
a chew mark. The only way it will shatter is if you soak it in liquid
nitrogen and then drop it.
Plastic Sheet Dimensions
Cut out and drill per this drawing. Your mounting screw selection will
dictate the your mounting screw hole sizes and actual locations. The
mounting screw holes can be chamfered if using wood screws.
Assemble per the drawing below. Use hardware that will not exceed the
materials overall thicknesses. Counter sinking the holes for putting
the wood strips on the ends is recommended. That way the hardware will
be away from the immediate surface and less likely to scratch or catch on
the router table.
The wood strips should be pulled in about 1/4 inch from the ends. This
will give an edge to be able to more easily pick up the fixture when done
routing. The strips work best when they are slightly under sized from
the thickness of the work piece (the bird body). By leaving the two
sides open, there is enough space for the wood shavings to blow out.
Use of the Fixture
1. Turning the router on and off are not included in these instructions.
2. Drill 2 each holes into the work piece (the bird body). The
hole should be large enough to accept the screw, but small enough that it
won't strip out.
3. Mount the work piece with two screws.
4. Put on your safety glasses, start the router and route one side.
Starting from the beak is recommended as there will be less breakage
5. Remove the work piece/screws, flip 180 degrees and attach to the
fixture to the work piece with the screws.
6. Route the second side.
7. Remove the piece.
Return to the Bird Ornament Patterns Cover/Index
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FULL SCALE PATTERNS
List of Recommended Woodcraft
Book by Patrick Spielman,
Patricia Spielman (Contributor). Paperback (October 1986)
Ornaments by Tom Zieg
Paperback - 64 pages (September 2000) Fox Chapel Pub; ISBN: 1565231236 ;
Dimensions (in inches): 0.21 x 10.94 x 8.52
Saw Basics, Mark Duginske, Gene Duginske / Paperback / Published
Saw Handbook, Mark Duginske / Paperback / Published 1989
Woodworking (Sunset New Basic), Paperback / Published 1995
Woodworking : Essential Woodworking Skills and Easy-To-Make Projects for
the Home and Garden, James Summers, Mark Ramuz / Paperback / Published
Keys to Preventing and Fixing Woodworking Mistakes, Alan Bridgewater,
Gill Bridgewater / Hardcover / Published 1996
Keys to Woodshop Safety, Alan Bridgewater, Gill Bridgewater / Hardcover
/ Published 1996
Weekend Gift Projects from Wood, James A. Jacobson / Paperback /
Woodworking Projects, Workbench Magazine / Paperback / Published
Original Shop Aids and Jigs for Woodworkers,
Rosario Capotosto, Michael Capotosto / Paperback / Published
Christian and Inspirational Patterns for Scroll Saw Woodworking,
Thomas L. Zieg, Tom Zieg / Paperback / Published 1995
Wooden Crafts to Make With Kids, Ellen J. Hobart,
et al / Paperback / Published 1994
Weekend Woodworking Projects, John A. Nelson / Paperback / Published
Yard & Garden Projects You Can Build Yourself,
Monte Burch / Paperback / Published 1994
Yard and Garden Projects You Can Build Yourself, Monte Burch
/ Hardcover / Published 1994
Routing (Art of Woodworking), Hardcover / Published
Routing : Techniques for Better Woodworking (The Workshop Companion),
Nick Engler / Hardcover / Published 1993;
Woodworking; Edited (Home Repair and Improvement), Hardcover / Published
in Woodturning : Techniques and Projects, David Springett / Paperback
/ Published 1995
American Country Woodworker : 50 Country Accents You Can Build in a
Weekend, Michael Dunbar / Hardcover / Published
Finishes : Techniques, Tips, and Problem-Solving Tricks (Woodworking Series
, No 3) Vol 1, Bob Flexner / Hardcover / Published 1996
and Bedroom Furniture : The Best of Fine Woodworking (The Best of Fine
Woodworking), Paperback / Published 1997
of Fine Woodworking : Bench Tools, Paperback / Published
Best of Fine Woodworking : Modern Furniture Projects (Best of Fine
Woodworking), Dick Burrows (Editor) / Paperback / Published
Didn't find your book? Type in the name of the title or
subject to search the