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Using the same center point and a stick to use as a compass for the marking
pen, I draw the inside and outside diameter circles of the outer edge.
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Using a
carpenters square that is against the center pin (arrow), I can draw the first radial
line.
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With my
compass lined up on that first radial line, I can run other lines at 30o
intervals — each representing 5 minutes of the clock dial.
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Now I
have all my radial lines, and they look good.
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Next, I want to create a template/jig that will represent one 30o sector. I use
the compass now set to 15o and scribe one line on both sides of the center
line.
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I
use the same marker to draw two circles that will represent the borders for the
"minute tick marks."
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I have
installed a 1/4" up-spiral bit in the router and a guide bushing of 7/16" O.D.
This gives the bit just enough clearance to spin freely. I am holding a 1/16" spacer.
I will make the template with this extra space in mind.
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I have found a scrap of 1/4" plywood that I will
use to make the template.
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This
photograph is very misleading. It doesn't show the dozens of marks of trial and error. I
think I finally have it right. The box on the left is for the 5 minute mark. The two
others will be two minute marks in-between. I will use the template once for these three
holes and then flip it over to do the holes in between — I think.
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I
am pleased to report that I just received a brand new product from Festool — The
Festool Trion PS 300 EQ Jig Saw. I have tried it for just a minute or so and
instantly fell in love with it. It has a splinter guard that can be modified for each
blade you use and acts like a perfect zero-clearance plate. With the right blade
installed it should be perfect for cutting out the Roman numerals for the clock. Before
that, though, I will use it to make the template for routing the minute "ticks."
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