54" Hybrid Build-Along

[beachbowhunter]

This is a great build-along.  Jon, where did you pick up that burr grinder bit?  I haven't had any luck finding one..

[JGR1269]

My Dad was in the auto body business for 45 years and I'm pretty sure I borrowed that from him about 16 years ago.

[rmorris]

Beach, I have seen them at Lowes form time to time , also in cylinder and cone shaped.

[JGR1269]

Here it is with the shelf finished up on the drill press with a coarse bit. I like to leave that little trough in the transition where the sight window and shelf meet. When the bow is finished and I put the strike plate and shelf pad on it will leave a nice area for the fletching to clear the sight window.





Now I clamp on my old recurve riser template and use some of the curves as a template.





Before I head to the bandsaw I use my grip template to mark the grip cut.



I also remark the tips 1" past the grooves so I can cut off the excess.



Time to make the cuts.

[JGR1269]

Before I quit for the night I peel the blue tape back and remark the tips for the overlays. I rough up the glass with some 36 grit on a block and wipe the area clean with some alcohol.



I cut my tip overlay block in half and go over the back side with 36 grit and alcohol.



Now I apply some epoxy and clamp the overlays in position. Before I'm done I remove the tape and wipe the excess epoxy off the glass.

 

[bigbob2]

Looking good!  

[bjansen]

Great build along.  Drilling that hole for the shelf is genious.... I always learn a new technique or trick each time I see a build along

[EHK]

Thanks for taking the time to post this Jon.  I love the hole for the shelf idea too.  Also, building the tip overlays out of a single piece and then cutting it in half is a great idea.  Good stuff.

[Swissbow]

Great job. Really appreciate the time and effort you put into this build along. Saw a few things I'm going to try on my next one.
__________
Andy

[Sant-Ravenhill]

Really enjoying this thread!

[chall]

Thanks for posting.

[JGR1269]

Bear with me guys. I don't get a lot of time to work on it.

[Mad Max]

Take all the time you need as long as you hurry up.

[Dan Landis]

Never worked with glass or even made a laminated bow of any kind, but I am thoroughly enjoying this build along.  Thanks for sharing.

[JGR1269]

Since my tiller is good and my limbs are straight, I can taper my limbs a little more from about 1" beyond the fades to the tips.
I retaped the limbs, marked the width and ran a straight edge from the fades to the marks at the tips and left a line to follow.



I take the material off on the disc/belt sander.



Now I clamp the bow to the bench and run a block with 80 grit on the limb edge to take out any high spots.



It's time to file the grooves through the tip overlays. I mark it out with tape so I have a good guide to keep them the same from side to side.



I file just deep enough so the top edge of the file is flush with the limb edge.



Now I connect the sides with tape as a guide.



I file all the way through the top layer of Bocote
until I hear the file hit the first glass layer.

[JGR1269]

I measure down 3/8" from the straight groove and put a mark.



I apply a piece of tape as a guide.



Again, I file to the same depth as before.



Using a rotary file I remove the center section.



Then with a square file I level it out.



They're roughed in for now and I'll finish them up when I shape the tips.

[chall]

Great stuff!

[LESKEN2011]

Good stuff, Jon. Keep it coming!!

[chackworth3]

Excellent way to do the tips!

[JGR1269]

I worked on my tip overlays for a couple hours this afternoon. I pretty much have them where I want them other than a little final tweaking.

I marked out the rough shape by tracing the edge of a roll of masking tape to get the curves.



Then I remove the material on the spindle sander.



I put a piece of 1" aluminum tape on the limb at the base of the overlay to protect the glass. After some filing, sanding and shaping I end up with it roughed in.



Then I go to work on the belly side of the tip where I file another groove track for the string to lay in. This will give the end loop a consistent place to lay at brace. Here you can see it on the left side of the string groove.



I do the same on the right side and rough in the rest of the belly side of the tip.



I may need to do a little finish work to make it perfect but I'll do that upon final sanding.



Tomorrow I'll go the work on the spindle sander and get the grip area shaped.