Today, in Part 4, we will talk about and show the making of the Rook.  First will be an image of the design and then some images showing how a table saw jig was made for cutting the slots in the Rook's "Castle" head.

 

The design shows  a 1 1/4" square piece of either Hard White Maple or Black Walnut 4" long in my 4 jaw chuck.  The Rook is machined and formed per the drawing using appropriate forming tools.

The next image shows the simple jig design that holds the finished Rook in the vertical postion to cut the slots on the table saw.

 

The next image shows how the rook is inserted into the jig, using locator marks.

 

The Rook is then rotated 90 desgrees and cut again.  I used a 1/16" wide blade.

Part 5 will show images of the rest of the Chess Set piece designs.

Larry

Neat Jig!!

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Lew Kauffman-
Wood Turners Forum Host

Time Traveler and Purveyor of the Universe's Finest Custom Rolling Pins!

Ingenious, I would have filed the slots, never would have thought of inverting the rook on the table saw. I take it you are just making one pass, the width of the kerf?

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John Morris
The Patriot Woodworker

Yes Sir!  I used a 7 1/4" circular saw balde that is 1/16" wide.

Larry

John Morris said:

Ingenious, I would have filed the slots, never would have thought of inverting the rook on the table saw. I take it you are just making one pass, the width of the kerf?

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John Morris
The Patriot Woodworker

Larry, do you ever experience tear out or chip out at the castle slots?

Larry Jenkins said:

Yes Sir!  I used a 7 1/4" circular saw balde that is 1/16" wide.

Larry

John Morris said:

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John Morris
The Patriot Woodworker

No.  The simple jig eliminates any possibility of trearout due to total encapsulation.

Larry

John Morris said:

Larry, do you ever experience tear out or chip out at the castle slots?

Larry Jenkins said:

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John Morris
The Patriot Woodworker

Of course!

Larry Jenkins said:

No.  The simple jig eliminates any possibility of trearout due to total encapsulation.

Larry

John Morris said:

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John Morris
The Patriot Woodworker

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John Morris
The Patriot Woodworker