Help!! I've started making a nice set of unit building blocks for my
niece and grandson out of 6/4 walnut and cherry. The unit block size
is 1-3/8 inches by 2-3/4 inches by 5-1/2 inches and all my other
blocks will be multiples of it. I want to make some of the Roman
arches and half arches out of a unit block. The problem I have is
that I don't know how to make each of them look exactly like the
other. Has anyone designed a jig which can be used on a band saw or
with a router to cut these shapes out? I want to make about 10 of
I would set up a sacrificial fence on your drill press and use large
fortsner or saw-tooth bits to cut half-circles. Use a stop block and you'll
get identical parts. You could also make the parts twice as wide as needed
and drill a circle centered across the width and then just rip the part in
half on the table saw.
A roman arch is a simple half-circle above the opening.
A 'gothic' arch has arcs that are the full width of the opening
the 'easiest way to get roman arches, is with the proper size drum
on a spindle sander. Ditto if you're making blocks with a quarter-circle
'bite' out of one corner.
Saw on the 'waste' side of the arch line,
Clamp a couple of stop-blocks to the sander table,
And then 'introduce' the block to the sander, until it hits both stops.
Thank you all for your input! I'll give the ideas a try and see how
it goes. Thanks again for your help, the kids should love the blocks
and I'm glad there are still people out there in this high tech world
willing to give others a hand :-)
Happy Holidays!, Don
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