whatdya make patterns from?

[Dale R. Hamilton]

Want some kind of sheet, thick enough so bearing of a router bit will be able to follow it, won't distort, edge crumble, change over time, and of course cheap. Plan on using big router table and feeding pattern on top of ply through bit.

Next ques- how do you cut your patterns out of this material so that they are perfect- well sorta
I planned on glueing the papper pattern down on the pattern stiff, and then cutting out slightly oversize with my jigsaw. Finally, plane down to the line as accurate as possible.

[ssor]

5 mm lauan plywood works for me. Use the best saw blades and work carefully.
how many duplicates are you planning? A whole bunch might require baltic birch.

[ 02-24-2005, 11:51 AM: Message edited by: ssor ]

[John Bell]

Never done it myself, but how about MDF? Instead of planing it to the final shape, use a drum or belt sander to get it down to the line.

[Thad Van Gilder]

I get scraps of this 1/8 inch marine ply for free. It words great.

-Thad

[Ron Williamson]

1/4" MDF that comes as cover sheets for the real material.
R
Edited to say that it edge planes and block sands easily and a belt sander can be a bit too aggressive.

[ 02-24-2005, 12:21 PM: Message edited by: Ron Williamson ]

[Bruce Hooke]

I frequently use 1/8" masonite. To make the pattern I like the technique of gluing a paper pattern down with spray adhesive and then sawing and sanding to the line. Masonite seems to shape well and hold up well to being run against the router bearing.

I should note that for the most part the stuff I have been making via this means has been relatively small and it has been the kinds of things where an EXACT match to a predetermined pattern is less important than a smooth, pleasing curve. This fact comes into play both in the paper pattern, which at least if printed on my computer never comes out EXACTLY at the intended size, and on cutting and sanding to the line, which always allows for some error to creap in. The former issue can be addressed by means like laying out the design right on the masonite. The latter largely comes down to careful workmanship.

[Dave Fleming]

Dale go to Pat Warner's web site. He is an acknowledged 'guru' of the router crowd.
As I have seen in his shop, he uses a good grade of MDF for all his patterns. He applies something like Watco or a thinned Poly to them before use. In fact the router table you will see on the web pages is made of that stuff and it is over 5 years old.

Pat Warner's web site (http://www.patwarner.com)

[Dale R. Hamilton]

wow- great ideas- Thanks Dave- checking the guru
now. Always admired the router workers- especially crosscutting plywood.