This is a bow I built for my brother in Oregon. I started by making some rough sketches of how I wanted it using some cut outs from previous builds.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/1.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/123.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/124.jpg)
I had a full panel of grey action wood, I made some cuts for my riser and wedge set, I then ground my wedges on my sled first into tapers and then made them into parallel wedges.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/11.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/12.jpg)
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[IMG]
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/16.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/17.jpg)
I then took some action boo flooring and ripped off the tongue and groove and them ripped them down to 1 ¾" wide on the table saw.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/18.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/19.jpg)
Next I resawed some a-boo and action wood rough parallels on my band saw.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/110.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/111.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/112.jpg)
The next step was to come up with a laminated veneer to go on the belly and back of the limb. I started with action wood split with a-boo and maple.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/113.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/114.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/115.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/116.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/117.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/118.jpg)
After the glue was cured I ran it through my drum sander and resawed it in to 5 lams, I ran one practice down to see how thin I could make them, I brought them down to .015"
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/119.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/120.jpg)
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(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/122.jpg)
I then received some materials to start the I beam of the riser.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/125.jpg)
I started with a 2"x2"x20" block and cut it in half length wise and ran I through my drum sander. I also ran my phenolic through the drum sander.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/127.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/128.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/126.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/129.jpg)
I cleaned all the parts with compressed air and glued them together. When cured I re ran it through the sander.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/130.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/131.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/132.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/133.jpg)
The next step was to make the I beam into a double radius curve.
I ran a test piece of boo to set the radius on my band saw swing jig.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/137.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/134.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/135.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/136.jpg)
Once cut I sand with a 40 grit block by hand. I then glued red phenolic and I think 4 parallels of .125" action wood and black phenolic to the back of the riser and glued it.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/138.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/139.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/140.jpg)
When it was cured it cleaned it up on the drum sander and added another 5 .125" parallels to the back and glued it up, when it cured I ran it again through the drum sander.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/141.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/142.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/143.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/144.jpg)
I then was ready to cut the second radius on the belly side of the riser.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/145.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/146.jpg)
After cutting it on the swing jig I hand sanded again and added one more strip of red phenolic and another stack of .100" parallels, the .125" would not make the tighter radius.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/149.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/148.jpg)
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(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/151.jpg)
Looking good.
I did not get any pictures of grinding the lams but I used the same drum sander with my dedicated 60 grit lamination sand paper. The stack up from belly to back goes. Clear glass, veneer, .002" per inch a-boo taper, action wood wedge, action wood parallel, veneer and clear glass. I used compressed air only to clean the lams.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/152.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/153.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/154.jpg)
Now I am a bit spoiled to have a friend with a Bridgeport mill for my drilling tapping and riser limb pad machining.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/155.jpg)
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(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/157.jpg)
The next step was to cut and grind some thin wood and phenolic to laminate together for the limb tips.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/158.jpg)
I glued them all together with plastic rap on the limb surface to get the correct limb radius. Once they are cured I taper them on the spindle sander.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/159.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/160.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/161.jpg)
I then measure where the string groove is and prepare the limb glass before I smooth on the tip material for a cold cure.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/162.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/163.jpg)
Next I lay out the limb shape and scribe it with a carbide scriber and cut it to shape on the band saw, I put on an old glass only blade for this. I cut very close to the scribed line.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/164.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/165.jpg)
I then sand to the line on the 6"X89" Jet.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/166.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/167.jpg)
I made a simple guide for my string grooves to use with a chainsaw file, I was very happy with the results.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/168.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/169.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/170.jpg)
I then relieve the file cut with a die grinder and 1" sanding drum.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/171.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/172.jpg)
Now it is time to shape the riser, I cut out the sight window with the band saw leaving the shelf high and staying away from the area where I would blend into the top limb.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/173.jpg)
I used a ½" router bit in the drill press to flatten out the riser and bring the shelf down, this riser is cut to center.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/174.jpg)
I then used a 1/2" ball nose carbide burr to put a ¼" radius on the inside of the shelf/sight window.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/175.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/176.jpg)
I then used a 40 grit 2" diameter sleeve on the spindle sander to shape the top of the sight window.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/177.jpg)
I would give my left cahoney for a shop full of equipment like that! Man, I'm so envious of you.......I know it's a sin to covet another man's possessions, but I just can't help it. :D
I like those limb veneers, they look pretty cool.
I used a wood jig with the spindle sander with a 3" drum to hold a consistent angle on the limbs.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/178.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/179.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/180.jpg)
I mounted the limbs on the riser and scribed the phenolic, and started to shape the riser using the spindle sander and rasps.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/181.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/182.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/183.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/184.jpg)
My wife snapped a picture of me tillering the limbs and took another picture of me pulling the bow on the tiller tree.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/186.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/187.jpg)
Here it is in the paint booth.
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/188.jpg)
The finished bow specifications are. 62" 50# @ 30.5"
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/189.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/192.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/190.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/191.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/194.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/195.jpg)
(http://i680.photobucket.com/albums/vv167/singlebevel/build%20along/193.jpg)
Excellent job, absolutely stunning.
Holy cow! If I had known that it was so easy I would have started making a bow like that instead of the ridiculously difficult board bows that I have attempted. :) I'm tired just after looking at all that work.
What an excellent pictorial and narrative. Thanks for sharing that. I love your shop and tools just like SEMO said.
I was going to ask you to adopt me until you showed the picture of yourself. I'm a lot closer to to being old enough to be your father. For some reason I expected an older fellow to be doing this.
Thanks again and great job!
Super job Dan!! :clapper: :clapper:
Fantastic :notworthy:
excellent! thanks for taking the time to post such a great build along
Sweet!
VERY nice job.
One of the best follow alongs.
Beautiful bow and craftsmanship, Dan.
Wow thats alot of work and a beautiful bow :clapper:
That is just gorgeous. Great build
That is incredable. Wow, what a nice looking bow. Thanks for taking all the time to post all of the steps in detail. The shop is nice too.
Thanks everyone for the kind comments, my "shop" is just my basement.
DJP that bow and build along is fantastic,it gave me some good ideas for a bow this winter. Thank you.
Dan you are a true craftsman, thanks for taking the time to post.
wow, im blown away! that bow is beautiful! and the build along was so detailed with plenty of pics. thanks alot. i might have to try that one day, way, way down the road of course.
Am always amazed at the talent on this site...This is not exception! Excellent work, and what a beautiful result!!!
Some of the details in the limbs and riser make that bow pop! Wow!!!!
WOW. What more does one need to say? Truly awesome.
That is cool. I love your band saw guide.
A very nice bow and one of the best buildalongs I have seen. Bue--.
Nice bow and process. Thanks for the build-a-long.
WOW!! :thumbsup: "Dear Santa.." :biglaugh:
Exceptional job on the bow.
Dan, That is a pretty great job you did on that bow and the build-a-long. Lots of good pictures and tips and tricks. Nice job.
I have to ask, what are the long "lathe" looking things along your basement wall? I am always curious.
Chuck
Wow another great talent !!!!
Great job
Awesome,you are a man with skills! your brother is very lucky.
very talented. u got some awesome ideas to speed up the process, again very nice work.
A lot of good information. Thanks for posting.
Go Tigers
Beautiful work and bow. Thanks for all the photos and info, very nice shop also.
Not too shabby. Keep up the great work. God bless you, Steve
Just great :clapper:
2 The Top
Absolutely stunning. good job.
I have looked at this a lot, and for the life of me there is one thing that I can not understand. One the band saw, you have a piece of wood with what looks like a 6" diameter piece of pvc on it, and I see where you are sawing laminates with it. How do you keep it running in a straight line? Or am I missing something?
QuoteOriginally posted by stringstretcher:
I have looked at this a lot, and for the life of me there is one thing that I can not understand. One the band saw, you have a piece of wood with what looks like a 6" diameter piece of pvc on it, and I see where you are sawing laminates with it. How do you keep it running in a straight line? Or am I missing something?
The PVC radius allows him to cut lams or veneers off of a board that is nor perfectly parallel with the fence. Kreg makes a similar fence, but Dans does the same thing for a lot less $$.
Great job Dan...and awesome bow!
Nice build along.
I really like the riser!
Just one word keeps coming to thought. WOW! Great bow, great build along and great "basement"!
Great job. Thanks for taking all those photos, I really enjoyed them!
This is a seriously cool bow! Awesome job! Thanks for sharing.
Great job,impressive setup.
Question on the bandsaw table radius cut setup..
do you only swing the jig or does the whole table need to swing??
VJ.
BO-R...the toggle clamps are screwed to a block of mdf and that is screwed to the plywood, all of that swings on a pivot that is not shown in the picture.
great build along. I learn something new everytime i follow one of these. great shop. I wish mine was that clean.
Awesome!!! Great choice of materials!!! :clapper:
I am soooo jealous of artistic guys. Great job!
Nothing more I can say.
TTT
That is an awsome bow!! Where did you get that slab of actin wood?
This was inspiring. TTT
Thinking of doing another build along with a one piece design...anyone interested in seeing it?
QuoteOriginally posted by DJP:
Thinking of doing another build along with a one piece design...anyone interested in seeing it?
Count me in... Looking forward to another one.
Always interested in seeing how other do!
Im also curious about the band saw with the round pic jig .
A superb bow and buildalong. Thank you.
I've always been intrigued by and enjoyed designing and using jigs. I haven't started building bows yet but I'd like to see a thread here on jigs and forms used by different members.
Bring it on :)