Another idea would be to make the inner layer a solid circle and stack the rest on top in layers all precut.

Herb

Checked my circular saw this afternoon.   If it won't cut all the way through with a plunge cut, it'll come within 1/4" of doing so.   I can use that to cut the straights on the spokes.

3 hours ago, DAB said:

 

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

 

cheap, fast, good.  pick 2.

Classic STEM vs artist discord.

Your jig saw won't cut 3/4 plywood? 2 outer rings plus one inner spokes?

Herb

Edited March 6, 20179 yr by Dadio

10 hours ago, Dadio said:

Your jig saw won't cut 3/4 plywood? 2 outer rings plus one inner spokes?

Herb

3 layers of 3/4" OSB (standard material #2) -- already glued together.

My big concern is blade drift to the side down inside  the layers.

i'd just stare at the artistic director for a moment, and ask him if he's so smart, why doesn't he do it and leave me alone?  you come to me because i'm the expert on how to build stuff, so listen to me.  you can tell me what you want done, but not how to do it.  otherwise, you don't need me.

1 hour ago, kmealy said:

My big concern is blade drift to the side down inside  the layers.

 

Bosch jigsaw and w/ a Progressor blade matched to the job/material/cut.....

 

JIGSAW BLADE GUIDE.pdf

Edited March 6, 20179 yr by Stick486

On 3/4/2017 at 4:43 AM, Fred W. Hargis Jr said:

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.

I vote this solution.

On 3/4/2017 at 1:50 PM, kmealy said:

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.

Thanks for your effort Keith!

On 3/5/2017 at 1:20 PM, kmealy said:

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.

steel pipe with a tee in front would work just as good. easy to bend too. attach to chariot with u bolts.

 

Finished up the wheels this morning.  I would have preferred a bit more delicate wheel with smaller spokes and rim, but the set director invoked rule #1 (safe for the actors).   If they ever have another play where they need a manure wagon, they can use these wheels

 

The blank slate

Layout using compass and straightedge (we all use math)

Drilling corners

Plunge cut spokes with a circular saw

Cut curves with Progressor blade (Thanks, Fred, it worked great!)

Final result

 

Edited March 13, 20179 yr by kmealy

Good deal....Director should be happy.

1 hour ago, Fred W. Hargis Jr said:

Good deal....Director should be happy.

He's a decent carpenter (though not by profession) doing walls, risers, and steps, but I think this one had him stumped.

 

Next is the S-shaped chariot "tongue."   Prototype is like this.   FWIW, I'll be using sine function to determine length of riser piece