Zygi
Ex Member
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Randy,
I'm out here, I've been following yours and Mike's progress everyday. Lets just say your going to have one fine set of Imperial SO's when you all are finished. Mike's doing a fantastic job by any woodworkers standards!!!!
My method might have been just a little bit of a variant from Mike's method, yet essentially the same. The jigsaw/pattern cutting method works well for all kinds of irregular shapes and you can get multiple pieces all exactly the same. What I did was take and make a circle with an 1/8" larger radius then the out side dia. of the driver. I then layed out the football shaped cut out on a piece of scrape as well as on the finial piece. I then take the piece I cut with the 1/8" larger radius cut it down so it will lay on my lines and pin nail the pieces on the scrape piece of wood and flush trimed them to shape. You've now made a template for the football. Place the template on the actual piece, trace the lines, jigsaw all the excess material away, clamp the template in place and flush trim the rest of the material away. From there out I use the actual piece to trace the lines and use it as the template for flush triming the rest of the pieces.
You can use the same method for straight cuts with lots of angles, such as the driver cabinet on the Imperials. It is also the inside flare of the horn and there are no 90 degree angles anywhere. Just lay out the lines as per the drawing. Jigsaw outside the lines (I don't like to leave more than an 1/8" outside the line) pin nail a 3" wide straight board right on the lines and flush trim right to the line. When you have it all flush trimmed you have a perfect pattern and can make all the rest with exacting percision.
When you have inside angles meeting each other, you will have the radius of the flush trim bit left in the inside corners. You can either saw/file/sand to the line, or use a roundover bit and round the edges of the wood to match the pattern, the latter is my preferred method. On the Imp's this is not necessary, as the inside cutouts are just for driver clearance.
Hope this helps,
BobZ
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