DaveH6
Trimming windshield frame top edge
The task was to trim the windshield frame to the inside curvature of the pilothouse roof and account for the aft rake of the frames. All this along with the port and starboard frames angle with the center section. With my choice of a varnished mahogany windshield frame, extra care required in trimming the frame's top edge. Had I choose to use a painted frame, I suppose easy to patch in and fair wood to fill air gaps.
The router worked as expected with no bodily injury and only one case of minor tear out from the bit. The whole process took far too long but today I rationalize that I will be rewarded by an easy fitting of the roof. Not ready to declare victory as the truth will only be known when the pilothouse roof is fitted.
Though I have researched woodworking forums on techniques for keeping 1/4" shank router bits from slipping, I have had marginal success and more than one piece of wood ruined by my Porter Cable router letting bits slip. Ironically, the pictured Harbor Freight cheapo router has yet to allow bits to slip.
The windshield frame endeavor fried my brain with too much stuff going on. I talked to my brother James who enjoyed his studies in Quantum Physics ( whatever the hell that is) about the various angles, rake and deck curvature issues in play. He discussed the approach of using math and a computer to print out templates for the frames in lieu of my router trimming, plywood patterns and trial and error fabrication approaches. Since I'm the poster child for the truth that you can't teach an old dog (especially one experiencing daily brain cell loss) new tricks, I shall continue my dependency on the process of trial and error fitting via cardboard and plywood patterns.
*Edit 3/18/2013: The first fitting of the roof validated my technique for windshield frame top edge trimming via router. The frame may require only very minor tuning to create a close tolerance fit with the roof thus no shimming or serious planning required.
Trimming windshield frame top edge
The task was to trim the windshield frame to the inside curvature of the pilothouse roof and account for the aft rake of the frames. All this along with the port and starboard frames angle with the center section. With my choice of a varnished mahogany windshield frame, extra care required in trimming the frame's top edge. Had I choose to use a painted frame, I suppose easy to patch in and fair wood to fill air gaps.
The router worked as expected with no bodily injury and only one case of minor tear out from the bit. The whole process took far too long but today I rationalize that I will be rewarded by an easy fitting of the roof. Not ready to declare victory as the truth will only be known when the pilothouse roof is fitted.
Though I have researched woodworking forums on techniques for keeping 1/4" shank router bits from slipping, I have had marginal success and more than one piece of wood ruined by my Porter Cable router letting bits slip. Ironically, the pictured Harbor Freight cheapo router has yet to allow bits to slip.
The windshield frame endeavor fried my brain with too much stuff going on. I talked to my brother James who enjoyed his studies in Quantum Physics ( whatever the hell that is) about the various angles, rake and deck curvature issues in play. He discussed the approach of using math and a computer to print out templates for the frames in lieu of my router trimming, plywood patterns and trial and error fabrication approaches. Since I'm the poster child for the truth that you can't teach an old dog (especially one experiencing daily brain cell loss) new tricks, I shall continue my dependency on the process of trial and error fitting via cardboard and plywood patterns.
*Edit 3/18/2013: The first fitting of the roof validated my technique for windshield frame top edge trimming via router. The frame may require only very minor tuning to create a close tolerance fit with the roof thus no shimming or serious planning required.