AW #131.pdf - Karatunov.net

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10. Cut the riser block to length. Find the center of
the bottom of the riser block and drill a 5,/lGin' hole'
1/2-in. deep to fit over the index pin on the lower
form. Tiace the shape of the riser using the pattern in
*re kit and cut the shape using your bandsaw. Sand
with a drum sander (Photo 4).
11.Tiim the wood laminations to 32-in. Then, cook
the riser and wood laminations in the heat box for
about 30 minutes to chase off any surface moisture
that might interfere with the epoxy set.
12. Cutboth bottom pieces of Bo-Tufffiberglass to
32-in. and the top piece to 64in. ADremel cut-offdisc
works great on the Bo-Tuff, but a pair of metal cutting
shears will do. Wear gloves when handling the Bo-
Tuff. Fiberglass slivers are a real drag.
13. The Bo-Tuff has a smooth and a rough side.
The smooth side is the finished surface while the
rough side gets the epoxy. Apply heat-resistant mask-
ing tape to the smooth side of the Bo-Tuff. The mask-
ing tape keeps epoxy off the surface and avoids
unnecessary cleaning and sanding
14. It's imperative to have everything (including a
helper) ready before applyrng epoxy to the bow lam-
inations. I like to set the form between blocks
clamped to a pair of sawhorses. This provides clear-
ance around the entire form so I can wrap filament
tape around the form and pull the laminations down
tight to the form. Test the pressure hose fittings for
leaks in a pail of waterjust as you would with a bicycle
inner tube. Also, rub a thin layer of paste wax onto
the plastic laminate and both sides of the metal pres
sure strip (Fig. B) to keep oozing epoxy from sticking
to their surfaces.
15. Roll out an ample length of plastic wrap over
the lower form onto the plastic laminate to further
protect it from epoxy squeeze out.
Frc. D Wtntruc DtRcnRvt
Q Ctr" the reverse taper strips to the lower form with contact
Jcement. Make sure the thin end goes against the index pin'
Add plastic laminate strips on top of the reverse taper strips to
create a smooth surface on the form.The steel index pin is used
to anchor the riser block in the form.
7,1 tne oow's
Ihandle is
shaped from a
large block of
solid wood
called a "riser
blocki' Sand the
riser with an
oscillating spindle
sander or a
drum sander. A
backer board
allows you to
feather the
riser's tapered
edges to a
paper-thin thickness.
(fn" bow is composed of three types of laminations: strips of
r-f solid wood of uniform thickness, strips of solid wood that
taper from end to end, and strips of Bo-Tuff fiberglass. Coat all
of these pieces with slow-setting epoxy.
AmericanWoodworker ocToBERzooz 61