I have more Morse Code blanks left from my previous build. Rather than letting them sit around the shop I’m choosing to get them built. They blanks are all at least 6 inches long so this edition is six inches thick. The last one was 4 inches. While the Morse Code blanks are ready to go, I have to build up the chaos pieces. I have covered the process before – here is how this one is going.
The width of the blanks is set by the longest Morse Code word. With the blanks finished I set up the clamping order.
You can see the 3rd word up is shifted to the right. I glued the filler on the wrong end of the word. Oh well. Now I can begin gluing the block. I glue one layer at a time. I’m using plastic blocks to keep everything aligned while clamping.
Several glue-ups later the main block is done. About half way through I leveled the block. The small differences in size had accumulated and there was a bit of a bow across the face.
The next step is to add chaos panels to each end of the block.
Next I add some border panels. I have a layer of maple surrounded by a layer of cherry. Now I can split the 6 inch block into 2 blocks 3 inches thick. I’m using my tall fence to help keep the block aligned.
I make a pass on all 4 faces and finish the job with a pull saw.
Now I can level the faces with the drum sander.
After I square up all the faces I have 2 blocks ready to slice apart.
The same process is used to end up with 6 cutting boards.
I have enough material left to make a couple smaller boards as well.
That wraps up the build notes for this set. They are always much appreciated as gifts.
