I am currently helping build props for a stage company.   They like to build everything from 3 basic materials:  2x lumber, 1/4" lauan, and 3/4" OSB.    Everything is generally screwed together so they can take it apart and reuse what they can.  General rules:

1. Safe for actors
2. As long as it looks good from 50 feet, it's great.

 

My current task is to make some spoked 36" wheels for an Egyptian chariot that will hold one of the actors.   Last week, I laid up 3 layers of OSB and cut the outside circle.   The plan is to cut out 6 triangular pieces to make the spokes and hub.

 

My problem is what to use to saw out the spokes that will cut the 2.25" thickness without the blade wandering.  Any suggestions? 

 

I will definite drill out a 1" or so hole in each apex to make a smooth curve and not concentrate stresses.

 

Some options:

• Template with a router with bearing or guide and plunge down through levels.   Don't know if I could get a long enough bit, though.
• Jigsaw or reciprocating (Sawzall) saw, maybe drilling holes every inch or two
• Plunge cut with circular saw as deep as it would go and jigsaw the rest and curves.(inside edge of rim)
• Drill lots of holes and smooth out the triangles between them

I really like the way you guys are starting to use the editing software, look at you Keith, with your bullet points and numbers and all! Outstanding!!!!!!!

I need to think about this one, as far as the wagon wheel goes, great topic!

Can you pull apart the layers? I could see cutting 1 layer out then using a template router bit for the others - that would be my 1st choice

I would create a template and rout out the waste. if you pre-drill the corners and template you should be able to precisely locate it from each side reducing the depth of cut by I/2

 

another thing would be to use both top and bottom guided bits to cut the holes

Use drill bits to get the radius, and then a jigsaw with a Bosch T345XF3 blade. These blades have 4 1/4" of teeth, thought they have a variable TPI and should give a smooth exit cut, with a rougher interior cut; and I'll bet the beat the hack out of trying it with a recip.

Edited March 4, 20179 yr by Fred W. Hargis Jr

A template and routering from both sides would be my choice. 

Top bearing pattern bits with a 2.5" cutting surface are available.

If you wanted, you could get another one with a bottom bearing to cut from the other side. 

 

Holes, then jigsaw, paint, then at 50' you can't see saw marks anyway.

https://www.amazon.com/s/ref=nb_sb_noss?url=search-alias%3Dstripbooks&field-keywords=making+and+modifying+machines

 Don't know the details of your situation (do you have time, money, and space) but, have you considered a walking beam saw? Basically a ginormous scrollsaw that uses lengths of bandsaw blade. The above book features plans to make you own.

Hmmmm - made some wagon wheels once - similar - drilled the corners and jigsaw the rest - wander? - clamp in a guide rail.

Just my 2% of a buck

 

18 hours ago, John Morris said:

I really like the way you guys are starting to use the editing software, look at you Keith, with your bullet points and numbers and all! Outstanding!!!!!!!

I need to think about this one, as far as the wagon wheel goes, great topic!

Years ago, I had to do a lot of technical writing.   I found "Plain English" guidelines from the US Govt. https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0ahUKEwjLuoOR6r3SAhUe3YMKHX6PCrwQFggfMAA&url=https%3A%2F%2Fwww.sec.gov%2Fpdf%2Fhandbook.pdf&usg=AFQjCNEFt6a73Wqgso_OJriMIp7r0qKn6Q&sig2=Kvw5pQsCEuH8nDt3mJyS8Q   It did more in the hour or two it took to read it to clarify my writing than 13 years of English classes.

 

I dropped out of a forum once because there was a guy who had to comment on everything.   He could never get to the point.   This is one of my pet peeves -- people that drone on and on.   To make matters worse... he would just interrupt thoughts with ellipses...jumping from one thing... to another... then starting off on something else... and to repeat himself...over...and over... and over...just one giant paragraph...lacking in any punctuation...except ellipses.    If someone is not going to take the time to write something clear, then 50 people should not take the time to struggle to decode it.

Edited March 4, 20179 yr by kmealy

Make your point clearly and concisely. Then shut up.

Had another thought:  at 50', can't tell details.  Don't cut it out; paint the spokes a dark color, the "spaces" light/neutral.  The eye will know what you mean.

1 hour ago, PeteM said:

Had another thought:  at 50', can't tell details.  Don't cut it out; paint the spokes a dark color, the "spaces" light/neutral.  The eye will know what you mean.

 

yup.

 

or just use 1/4" ply and attach to an old bike wheel with some wire.

1 hour ago, PeteM said:

Had another thought:  at 50', can't tell details.  Don't cut it out; paint the spokes a dark color, the "spaces" light/neutral.  The eye will know what you mean.

A really good idea, would probably be a lot easier.

4 hours ago, PeteM said:

Had another thought:  at 50', can't tell details.  Don't cut it out; paint the spokes a dark color, the "spaces" light/neutral.  The eye will know what you mean.

That was an original proposal, shot down by the director.

So have you formulated a plan?

blade wandering?  who is doing the jig saw work?

 

15 minutes ago, Fred W. Hargis Jr said:

So have you formulated a plan?

I'm going to pick up materials next weekend and bring them back to the shop.   My first try will be with the Bosch blade you recommend.  Also need to make a "tongue" to go under the chariot and have a bar for slaves to pull it around with.  Needs an s-shaped curve in the middle.   Sort of like the scale model I tried.   Basic material #1 -- 2x4 lumber.   Bridle joints if I can fit them on the saw and floating tenons if not.

5 hours ago, kmealy said:

That was an original proposal, shot down by the director.

 

fine mr. director, you make it if you are so smart.  

 

cheap, fast, good.  pick 2.

7 hours ago, kmealy said:

That was an original proposal, shot down by the director.

If I was doing it ,which I am not, I would cut the center hub and spokes separate in one piece . then cut the outer rings with out spokes and center hub. Do as many layers as needed and lay a ring down, stack a spoke on it, fill in between the spokes with a cut up ring. Stack them however works for thickness and an outer ring goes on top.  You get the idea. You can even finish paint as you go. Just a suggestion.

 

Herb

Edited March 6, 20179 yr by Dadio