Finally getting around to my bass build

[dadagoboi]

IMO kerf cuts have to be deeper, wider, and more consistent where needed.  Making them with a thin kerf plywood blade on a table saw using a stop jig and miter gauge is the way to do that quickly and accurately.  Judging by your photos you should be able to get the radii you need with no problem.

Like this only cheaper:
http://www.amazon.com/Freud-LU79R010-Ultimate-Melamine-Perma-Shield/dp/B000GJTIIK

[Highlander]

... Where's that damn global warming when you need it?   

18c/64f here today, not that I believe all that GW nonsense... Since the autumn/fall, I've had to scrape the windows just the once... plenty of rain, mind you...


+1 on the deeper cuts...

[drbassman]

IMO kerf cuts have to be deeper, wider, and more consistent where needed.  Making them with a thin kerf plywood blade on a table saw using a stop jig and miter gauge is the way to do that quickly and accurately.  Judging by your photos you should be able to get the radii you need with no problem.

Like this only cheaper:
http://www.amazon.com/Freud-LU79R010-Ultimate-Melamine-Perma-Shield/dp/B000GJTIIK

I'm gonna stick with my band saw with a stop installed.  The table saw is in the barn and I'm not working out there in the winter.  The kerfs I did yesterday worked, so far so good!

You have to clamp the wood till you use it or it wants to bow.  I might take a crack at it tomorrow.  I'm letting it sit clamped overnight to get a bow out of it from shipping.

[Lightyear]

Actually, the wood isn't wet, it's been plasticized by the compression process and is totally dry to the touch.  While it is bendable, it is not damp or soft.  Bending it takes some muscle/force, but it does work.  My problem will be the horns.  If I can't get the radius I need, I may not be able to use this product.

I thought from reading on the company's web site there was still a certain amount of humidity left in from the plasticizing process?

[drbassman]

I thought from reading on the company's web site there was still a certain amount of humidity left in from the plasticizing process?

There is but even when clamped, no moisture surfaces.  I've cut and clamped the heck out of the test pieces and they are essentially dry, no dampness.

[drbassman]

Ok, I've been reading up on kerfing.  I am going to try a thin kerf blade on my table saw.

[drbassman]

I tried the thin kerf blade route on my table saw and the plasticized wood didn't like it.  The wider cuts caused uneven bending around a corner.  I actually had much better luck with kerfs made on my band saw.  It was good to try both though.  i wanted to be sure of my approach before I dove into the project.

[Dave W]

That doesn't surprise me. Of course I don't know the product but the thinner the cut for an operation like this, the better.

[drbassman]

That doesn't surprise me. Of course I don't know the product but the thinner the cut for an operation like this, the better.

Yep, with the wider kerfs, the wood buckles on the top at each kerf when you bend it.  It doesn't with the thin cuts.  This is something you don't see with non-plasticized wood.

[drbassman]

Well, after messing with the short test strips, I was concerned this stuff wouldn't work.  But, it did, to my pleasure and surprise.  I set everything up with my band saw first:  depth stop and ruler.  I cut my kerfs half way through, 2mm apart.  Worked perfectly.  Bending the wood around the form was more than easy.  I was really surprised.  It took me less than 40 minutes to do the entire thing:  measuring, cutting, bending, doing some more cutting, and more bending.  I am impressed with the way this stuff responds.

My one big concern was the wood, due to its length and thickness, wants to bow up on the ends.  By clamping it over night in a reverse bow, most of it was gone and I could work the rest out while going around the form.

Here are some shots:





Having a form handy helped with some pre-bending









More pics in next post............

[drbassman]

And finally................

[Pilgrim]

I nominate Bill for the new title of "Uberclampenfuhrer."   

[drbassman]

I accept!

The wood and form are now baking in a makeshift styrofoam box I made with an oil based heater inside.  Around 100 degrees for a night should cure the wood properly.

[Dave W]

Nice clamping job on the horns.

Overall, proof that you can never have too many clamps.

[drbassman]

Nice clamping job on the horns.

Overall, proof that you can never have too many clamps.

Thanks Dave.  It worked out better than I could have imagined.  It will be fun taking it out of the form tomorrow and gluing the bottom on.