Back to the tailgate panel build. This story left off with the completed blank for the trim around the logo. I chose to use the CNC to cut the inner and outer circles. This would ensure the circles would be concentric and sized to fit the logo.
I got the blank firmly clamped to the spoil board and started my cut.
Except my clamping was not as secure as I thought! Disaster strikes!
After a brief grieving session I went about making repairs. First mark the damaged segment.
I cut it out and use the disc sander to match the original glue line.
Then I need to remove the half segments on the bottom layer. I set up a guide on the glue line and used my trim router with a guide bearing. The guide board is on the left. The board on the right is to support the router.
I carefully sneak up on the depth of the cut.
Luckily I had some spare segments left over from the original build. I put down a layer of saran wrap and clamped the blank.
First the top segment is glued in.
Then the two backing pieces are added.
Now I can get back to the CNC. I re-center the after adding another clamp. Then the outer profile is cut.
Finally I have my trim ring!
Well, almost. I had some chip out on one area.
I smooth out the damage, make a patch and glue it in.
After sanding it to shape it looks good.
Now I need to get the back of the ring to match the curvature of the tailgate panel. It’s the same technique as for the logo. I tape a piece of 60 grit down and start sanding.
Once the back side matches the panel contour I use a rasp and sandpaper to give the ring a constant thickness at the outer edge. The inner circle keeps a flat profile.
Now I can install the trim inside the borders of the panel. I start with the straight pieces and use the ring to keep everything in position. Magnetic clamps are again in use. This is a test fit.
I mask off the panel to limit the cleanup of the epoxy squeeze out.
All the trim pieces get coated in epoxy and sanded smooth.
After the straight pieces are mounted I have to clean up epoxy at the joint for the trim ring.
I use some creative clamping to mount the trim ring. The ring is too thick for the magnets to work well.
Now the panel comes off the forms and the back side can be cleaned up.
There’s a significant step at one of the trim joints. Rather than just sand it down I added a thin filler piece.
The panel is outside for adding fiberglass cloth to the back side.
All that’s left is some trim and clean up. That’s all for this panel’s update!
Nice recovery Steve, no one will ever know this was repaired, impossible to see it. I've discovered that very seldom does a project work through to completion without something going wrong, but also in woodworking a recovery is always possible - you just need to think it through. The only other valuable point regarding woodworking mistakes that seems relevant here is that the mistakes are not as severe when using hand tools, as they are when using high speed & very aggressive electric Oopsmobiles. Looking forward to seeing this chicken magnet when completed.
