[kolias]

I’m making a wooden clock as a hobby and the attached indicates part of the clock’s face. The plans I bought came in 8.5”x11” sheets in full scale and I had to cut/glue them together to form the parts. What you see in the picture is about 14”x12” wide which I will glue to 1/2” Baltic birch ply for the final cut.

None of the curves you see are proper circles and that’s the problem. If they were proper circles I would use my router on a jig I have which cut circles up to 36” OD but on curves how can I do the cut?

I could use my band saw for the rough cut and then use my sander to finish but I don’t think it will be perfect.

Any suggestions?

 

[kolias]

Thank you, so it will be band saw/sander

 

[kolias]

The reason I didn’t mention a template before was because I would have the same challenge to make the template accurate. However I see the point here and I may go for it since I want the curves to be perfect.

This is the second clock I build, the first had 16 gears ranging from 9”OD to 1”OD. It is a challenge to cut all these teeth but I made my own 3 wheels mini band saw with a VS DC motor and I use either a Bosch 59.5” long blade with 6TPI 1/4” wide 0.012” gauge or a Vermont American blade 59.5” long, 15TPI, 1/8” wide, 0.012” gauge. I use the 1/4” blade for rough cut around each gear and the 1/8” blade for the teeth and of course lots of sanding... The current clock has only 9 gears. The band saw is happy with 1/8” thick material, it struggles with 1/4” and forget about cutting anything 1/2” thick; its purely for small hobby projects and luckily all gears I had to cut were 1/8” thick.

The patterns came thru mail from California, about 30 pages all actual scale which I print as needed and glue to the material. It turns out that my printer does not distort the scale of each pattern (I was told that some printers do change the scale not by a lot but enough to create problems during the assembly).