Ray's Woodworking

All Guides - Start Here

Beginning

Tools

Tool Guide

Wood

Sign Designs

Methods

Tool up Suggestions

Routers:

• Large for shaping edges, background material removal and creating patterns and templates
• Dewalt DW618, DW616

• Dewalt DWP611 (Porter Cable 450)
• Dewalt DCW600B 20V Brushless
• Bosch Colt PR10E, PR20E 1.0 HP
• Bosch GKF125CEN Colt 1.25 HP
• Makita RT0701C 1-1/4 HP
• Porter-Cable 690LR 11-Amp
• Rigid 2401

Mods

• Modify router bases by opening up the back
• make a 2" hole in the back 2" from the bottom
• Leaving the base plate intact, saw from the bottom up to the edges of the hole to extend the hole to the base

Router Base plates:

• Clear base plate
• oval 5 x 7.5 (regular small signs)
• raised side handles
• 12 x 12 (straddles large gaps)

Equipment

• Small compressor, hose and nozzles
• Chop or circular saw
• Table saw
• Band saw
• Angle grinder - sidewinder
• Circular and belt sander combo
• Belt sander OR Disc sander AND
• Palm orbital sander
• Drill & bits
• Shop Vacuum /air blower
• Heat gun
• Critter Sprayer 22032 118SG Siphon
• Dremmel or rotary tool for extreme fine detail, 1/8 or 5/16 bits and pattern cleanup
• Collet and bit sets for 1/8, 5/16 and 1/4 shanks
• Router base plate inserts
• Wrenches for collets
• A good, solid bench with vise & dogs
• Good overhead lighting
• Magnifier head strap
• Ear protection
• Safety glasses / goggles
• Safety face shield
• Respirator, face mask
• Sanding blocks and sanding sticks
• Kutzall shaping discs
• Belt cleaner sticks
• Diamond 300 - 600 grit stones
• Layout tools (ruler, yardstick, tape measure)
• Bench cookies / board covered in rubberized drawer liner
• Moisture meter
• Heavy nylon bristle brush
• Carving tool and X-Acto knife
• Magnifier head band or glasses to 5x
• Safety glasses, hat
• Portable goose neck lamp

Helper Tools

• Foldable lazy susan for spraying
• Jigs for corner cut out (2, 3, 4") jigs
• Reciprocating saw - sawzall
• Grinders, bench and sidewinder
• Anti skid drawer liner or mats
• Sanding board to hold tight
• Sanding sponge
• Paint standoffs or carpet strips

Laser / CNC

• Laser Pecker
• Atomstack
• Bobs CNC
• Fox Alien
• Genmitsu
• Nextwave cnc
• SainSmart
• Shark

Cleaning

Video 73

• Keeping the resins off of the bit reduces heat and further build up:
• Clean bits will last 3 - 4 times longer between sharpenings
• Use a dremmel brass wheel to polish the flutes after each use and especially before sharpening.

Sharpening

videos 8, 164, LTS8/27/17, Cofee & Questions 12/13/17 (dull bits)

• Keep cutters sharp
• Sharpness test: Use your fingernail and rub the bit against the surface. If it cuts / shaves or it drags it is sharp enough. If it is smooth it is dull and needs sharpening.
• Carbide cutters = diamond wheel
• Use 600 grit diamond jewelry wheel
• Grinding wheel available here
• Grind at the center of the wheel or slightly below to give clearance.

Profile bit:

• Sharpening shortens the bit = wider cut in wood
• 2 flute
• The bit is 15 deg on the side with 45 deg tip
• Sharpen flat side, not profile
• Sharpen the 45 tip first, then the 15. Barely touch and then turn it.
• Do the 15 degree by dragging across the wheel and turn it.

60 & 90 Degree Bits:

• Use a very light touch at exactly the center of the wheel
• Move side to side until a new surface on the cutting edge is formed
• Roll out very slightly as the grind is finished to create clearance for the cutting edge.
• Clearance is the same as for a drill bit, @ 5 - 6 degrees to let the chips clear away from the cut
• Not enough that it catches the other flute
• Repeat on all 3 flutes

Chamfer bit:

• Remove bearing and shank
• Use a diamond fine hone
• Lay flat 90 deg and roll off
• Do the same amount on all flutes

Tool Tips

• Re-sharpened bits = fatter, wider cut
• Roto tool might not = die grinder. Power carving may wear out the smaller tool. Die grinder is 1/4 inch collet.
• Use gasoline or Gunk Engine degreaser for cleaning ink and paint build up on nozzles, wood letters & patterns
• Use primer - not paint. Paint has carriers that gum up sanding discs and belts
• Causes bleeding through grain absorption

Routers & Rotary

Palm vs Full Size

• Worn bearings are not for fine detail work; shaft has runout and is floating
• Patterns and fine detail work need top quality bearings for longevity
• Larger routers are great for cleanouts with flat bits.
• Use the bigger routers for larger 1/4 and all 1/2 in shank bits
• Standard backgrounds use 90 Deg. for cleanout. 90 is also used for outset and very large inset letter cleanouts.
• Work from the center out to support 1/2 of the base resting on a flat surface
• Chuck the bit at about 1/2" to keep the motor away from the base
• Keep Bits Clean. Gunk spray or Oven Cleaner removes resins and pitch
• Use a dremmel brass brush - chuck bit in the router (unplugged) to hold it still

Rotary Tools

• 3/4 - 1 hp Rotary All in one
• 1+ hp Power Carvers
• Rotary tools - Dremmel

Carving bits:

• A small brass brush will help bits last longer

Angle bits:

• Can get into tight corners
• Can be lifted up during the cut to create finer lines at line ends and sharp corners
• Can be lifted out easier without damaging the sides of the cuts
• Can be sharpened
• 1/4 shank bits
• Profile bit 15 deg (tip is 45 deg)
• Cove, roundover or 45 deg chamfer
• 60 deg v-groove
• 90 deg v-groove
• fine pattern bit (SC50 Whiteside) OR
• carving liner

Bits and supplies can be purchased from the Make a wood sign site

• All carving bits are cut at an angle except the spiral bits.

Spiral bits:

• Use 1/4 shanks for all signs
• Carbide straight bits will snap if stressed or horizontal pressure
• 1/8 and 1/4 upcut and downcut
• Cut flat, creating flat-bottom carvings
• Use upcut 1/8 and 1/4

Spiral bits Pros and Cons:

Pros:

• Cuts all material very well
• Cuts flat for outset and inset
• Takes out much more material
• Sharper lines with steep (90 deg)edges
• Great in tight spots

Cons:

• Cuts effortless in soft material so it needs very careful control
• Going in and out of one spot needs to be exact
• More likely for the letter to chip during sanding due to sharp angles
• Easy to over spray
• Sanding dips on the surface can chip out or change sharp edges
• Can't be sharpened

Rasps / power carving

• Kutzall sells these
• Rasp Burr bits; nose, ball and flame
• Extreme shaping discs (4 1/2) for angle grinders
• Because of the bit angles (under 180 degrees), all angle bits leave a groove in the wood.