[DesertRatTom]

When I first read the word clock, I was thinking gears and making smooth gear teeth in BB ply seems a real challenge. But this pattern is smooth. It's open on the bottom so a band saw cutting close to the line, then sanding looks the way to go to me. A pattern is in order if you're making others, but using a pattern will present the same challenges as cutting with the band saw on the original. It's all those inside curves. You will need either a small blade, plus a lot of sanding to smooth out the curves, or a little wider blade that will make a smoother cut on the long curves, but require considerable sanding in the tight curves.

I think you could cut with a wider blade for the long curves, leave extra space for the tight ones, then change blades and do the tight curves. Here's a blade guide for curves.

For sanding I suggest you glue sandpaper to sticks for final sanding. I think a spindle sander is too likely to gouge if you press too hard or have a lapse of attention or a distraction. Straight sticks and then sand a few rounded as well. Use a finer 150 to 220 grit so you have good control and can't over do it.

Did the pattern come in pdf form so you can print another copy? If not, I'd make a copy of the original, just in case, before starting. You can get 3M removable spray adhesive that won't spoil the surface when you lift it off.

That's my fifty cents.

 

[DesertRatTom]

Home made tools are very interesting. For me, however, one of the best purchases I've made in the past few years was a medium size, 12 inch, Rikon band saw. It uses a 72 inch blade and is really nice and accurate and will handle pretty thick stock. I've even been able to resaw with it successfully. It is identical to the WEN (pix) which was a little cheaper. I have a 14 inch Laguna, but for fine projects I prefer the medium size bench saw. I usually run a half inch blade, but have a 3/16th blade for the fine stuff. The1/8th blade is too easy to break if you overtighten it. The picture shows the version with a stand. I have a number of WEN tools and they are very good, especially for the money.