OK, here is the second glue-up of the 7-day clock project. Used up the rest of the cedar 2X4 stud. This time I cut the step rabbet on the TS first instead of later with the router. Will have to report that it is a better way to go. But and there is always a BUT, it took 7 trips on each one for a total of 28 trips to the other TS to recut the mitered end after making the first miter cut. Also had to figure an extra 1" of waste per cut or a total of 7" + 1" for saw kerf or total of 8" mote per board.
Herb! Thank you for your report!
Looks like you have two rabbets along the backside... WOW! ... Yep, I can see how it's more work & waste to Route rabbets first than later...
Is it worth saving the Cleanup required when cutting the rabbets After the glueup?
I wonder if there is a SAFE way to route the rabbets After the main cuts and Before Glueup? If so, it might work out better Timewise and waste??
Your clock frame is looking GREAT! Perfect joints! The Jig worked really GOOD!
I have been thinking of just a simple Rectangular frame... using the Segment jig for FOUR segments... TWO Shorter in length and two Longer in length... They should fit together just fine! Yes?
If this works, then it should also work with EVEN Segmented Polygons, like EIGHT segments: Two Medium lengths (sides of rectangle), Two Long lengths (top & bottom), and FOUR very short lengths to be used in each corner... to make cooler corners. That should also work, YES?
Now, we can start to get it MORE complicated by making, for example, a 20 segment polygon with some pieces longer than others to create more of an Eclipse than a Circular result?? I think it's possible; the total sum of degrees would not change... the lengths would have to be equally balanced.
Lots of other ways of thinking about the use of these jigs.
Wheels could be made using say a 20 segment polygon, dry fit with tape, Determine center point, use Compass to draw a circle just inside the outer edge to make a Circle... make a router jig for the segment Curve, route all segment curves, THEN glue them up to have ROUND wheel! Yes?
Starts to really rely on ones IMAGINATION... doesn't it?