Let's do a build along...DONE!!!

[chackworth3]

A guy I'm making a bow for wanted me to take pics of the process so I figured I might as well do a build along for TG.  It's a 52" hybrid green mnt camo veneers with a-boo tapers for the core and mesquite/gmc riser.  Gonna be 45@27. This is what I got done yesterday afternoon and this morning...

Here is everything ready to go.  I start by putting green frog tape on the glass and marking center, 8 inches either side of center(in this case a 16" riser), and where the string grooves will be(26" from centerline).
   

Then I mark center on the glass and mark 1/2" at the string grooves...
URL=http://s1307.photobucket.com/user/chackworth3/media/DSC01404_zps7c2e232f.jpg.html]     [/URL]

...and 1 1/8" at the fades.
   

Then I go ahead and mark the limb profile( don't worry, I recheck it after it comes out of the oven)
         

[chackworth3]

Here are the blocks of mesquite and gmc marked with a center line.


Forgot to take a pic of it but I used a flexible ruler to mark a radius on the blocks and here they are being cut out on the bandsaw and shaped to fit on the sander... ignore the random radius and line drawn on the block, I changed my mind at the last minute:)
     

Here is the riser all clamped up ready for the oven...

and here is the final product after I epoxied them together with a piece of black glass as an accent...

[Dannon]

Love these build alongs!

[chackworth3]

I use the form to mark the profile of the riser's back and the flexible ruler to mark the ramps.  I go 1/16" one inch in from the fades and 3/8" two inches from fades...


Then it's back to the bandsaw to cut the riser out.
 

I get the back of the riser shaped to the form first before continuing to the fades...
 

Then I cut the ramps out on the bandsaw and get the fades paper thin on the sander...

[timbermoose]

lookin good.

[chackworth3]

I use a block and a disc sander to make a bevel joint for the a-boo tapers and the gmc veneers that are going to be on the back of the bow.

I use a little CA glue and clamp them together and just use a piece of glass as a straight edge...

[chackworth3]

Here is everything ready to be glued up.  I let everything, including the epoxy, get warmed up in the oven for about 20 minutes then pull out the epoxy and mix it in equal parts.  Then I pull out the lams and riser and wipe down all the glue up surfaces with acetone.
 

Gluing up.........................

I put down the back glass, veneer, and taper first.  Then I put on the riser and clamp it down to keep it from slipping while I tape it down.  Then I put on the belly taper, veneers and glass and tape it all down.  I double check the ramp area to make sure it and the riser didn't slip and to make sure there aren't any gaps on the ramps.  Then put some clear plastic wrap over it and put on the pressure strips and hose and inflate to 60-65 psi...

and here it is all in the form ready for the oven...
   

MORE TO COME LATER!!!!!!!

[D]

Awesome.  Looks great so far.  Look forward to the rest of it.

[kennym]

Nice build Chris! Yer GMC A/C veneers look darn good!!

[jess stuart]

Looking good thanks, for taking us along.  Can't wait to see more.

[Over&Under]

I like where this is going:)

[Trux Turning]

Really enjoy these build alongs- looking good!

[fujimo]

very cool- nice wood combo!

[Buemaker]

Interesting. It is almost half past nine in the morning and no new pics?            Bue--.

[chackworth3]

Ha! Didn't mean to keep you waiting Bue!  :D  
Ok. Round 2.  Here it is pulled out of the form ready to go
 

I hacksaw outside of the tips off and double check the center line
 

Then rough cut the limb profile on the table saw
 

and sand to the line on the belt sander...
 

[chackworth3]

Next I mark the string grooves at a 45 degree angle and rough cut them out with a chainsaw file



Then I prep the tip and riser overlay area by  marking it and sanding it with some 50 grit



Then I get the overlay materials ready by tapering them on the belt sander.  I'm using black phenolic for the tip overlays and some extra gmc for the riser overlay



I use CA glue on the tip overlays and clamp them down


Then I use the bow form to clamp down the riser overlay...

[chackworth3]

After all the glue is cured I cut out the string grooves


and rough shape the tips on the belt sander


Then I take a strip of 120 grit paper and shape the tips and blend them into the glass

[chackworth3]

Now I start the tillering process.  I measure at the fades and try to get 1/8"-1/4" positive tiller between the top and bottom limb



Then I put it on an 18" tillering stick and check the limb bend and make sure there is no limb twist


Then I start on the riser.  I mark 1 1/8" above center for the shelf and draw out the profile of the grip

[chackworth3]

Next I hacksaw out the shelf and cut the sight window out on the bandsaw.  I go about 2 1/2" above the shelf and about an 1/8" past center once it's all done.




Next I use a rasp to clean up the shelf area


Then it's over to the oscillating sander to shape the riser


I use another strip of 120 grit to smooth it all out


and here it is after it is all shaped out...


Ready to start sanding on

DON'T GO ANYWHERE!!! MORE TO COME LATER!!!

[Draffish]

looking good

i'm staying right here