This is a quick build that I had planned to make use of some basket weave panels I was making. The panel details are in a blog series.
I needed a new template for the top. I used a piece of 1/8" junk that I'm now glad I saved. Cuts fast with the laser and sturdy enough to use for making a proper template.
The laser makes the oval and centering easy.
Used to make a working template from 1/4" hardboard
DS tape to a piece of walnut, Forstner bit to drill out most of the waste in the hole, then a pattern bit in the router.
Template off, then a round over on both sides, sand smooth, done!
1/2" walnut strips, channeled on the router table to use as frames for the basket weave panels
3/4" cherry for corner posts.
Panels framed, then assembled with the corner posts. Some more router profiling, base frame added, top glued in place. I used picture tabs to hold the tissue box in place, though it is a close fit.
Dan, that was the prime motivator for the laser purchase, router templates. Too many hours spent trying to get curves right or fix issues with rasps and sanders. With the laser it's literally minutes laying out and a bit longer for the cut. Exact mirror copies are even faster and ideal for the ability to flip a part on the router table so all the cuts are "downhill" WRT the grain direction.
Well, then. I'd like to know which laser you used and an approximate cost. The booger-paper boxes I made, I used a Forstner bit and then a round-over bit on the router table. Got a good line, but it certainly wasn't a nice ellipse, just a slot with rounded ends.
Thanks for the complements guys! My tumble weed "fro" is embiggened 🤠
DL, This is the Ortur laser master 3, a 10 Watt optical power device. About $650 several years ago. This class of laser is one of a gazillion brands available.
For cutting the 1/8" hardboard, I only used it at about 1/2 power, but running slower or more passes also allows you to do the same cut with a cheaper unit.
I can cut the 1/4" hardboard directly and skip the thin "master" template step, but my thicker working templates wear out after a certain number of uses due to the DS tape occasionally ripping out chunks. It's also less wear on the laser since the devices "hour" countdown to death is lower.
I have no problems cutting templates on the TS if there are just straight edges, but fairing any curves is always a pain. I consider that work relegated to my minions, laser being my top chump at this time 🧐
The ellipse is a perfect example of a template I hate to hand shape. Another is the arched rails on A&C stuff. Seems everyone I make needs a different radius and setting up a trammel to cut the arch into a template is not something I consider fun anymore, especially when the radius becomes larger than 12"
Only thing easier I can think of is a full CNC cutter to just add the curves to the part directly.
