What would be the best way to Make these cutouts

[skip coyne]

Hi , I volunteer for a non profit and we have a program where we need aprox 150 of these cutouts a year for a fundraising program . We have had various volunteers making them with mixed results(often pretty bad and when you get them from a volunteer you have to smile and say those are GREAT , thanks so much ) . What I'm trying to do is come up with a way to work with a template , devise a cutting method and hand it to a inexperienced woodworker and get consistent results .

their cut out of 1/4 ply for reference the tile its sitting on is 12"x!2'

photos show cutout and end use

Thanks

[Kevin L. Waldron]

It probably might be easier to purchase these from a source..... they shouldn't be to expensive even for a non-profit......companies like http://www.brownwoodinc.com/custom/a...cts.asp?page=5

If you insist on having them made locally try people with lasers...(trophy shops or laser stores) Another possibility might be vocational schools if they have CNC equipment and you could probably get the students to make them. Cabinet shops would also be another source.

From a template standpoint an oversize/undersized template could be made using a laser or cnc with the exception of the right arm.....a router bit with a collar or a bit with bearing could follow the pattern but think your design is a little tight on the right arm...... A little redesign would probably allow this to work. (Best in-expensive material for template would be hardboard big box stores usually carry this in 3/16"-1/8" thicknesses.....1/4" would be better.)

Hope this helps.

kevin

[Mel Fulks]

Nothing wrong with the cut out,but is it really helping anything? The process I just went through was ....what is that ? Kinda looks like a turtle. Oh,yeah ,there's a pic of a turtle on it. Guess it's another turtle. I'd go to a rectangular 'bill board',like the pros use and spend the money on bigger posters, coffee and donuts, and helpin' people.

[Yonak Hawkins]

Don't overengineer this. Make a template to draw the design on the wood and cut on a band saw. Practice makes perfect. Find the most committed volunteers. The first 30 pieces may be woeful but, if you find a volunteer that's proud of her or his work, they'll stick with it and improve with each cutout. Each successive one gets easier and faster. I should think it wouldn't take more than 6 or 8 days, by one good person, to make 150 from knowing nothing.

[Al Launier]

If you could "open up" the spacing between the body & the legs a little bit you could make an aluminum, or even plywood template so that when using a router guide bushing against the template they could route the profile quickly & they would be duplicates.

[skip coyne]

that was my initial thought Kevin , we just got a quote @ 10.00 each , material cost for us is less than a 1.00 So it adds up . Ill give brownwwod a shout and see what they come up with . I've made hardboard patterns in the past and we may go that route .

Some great suggestions , thanks. we're good for this year so I have time to source it out

[skip coyne]

Thanks mel but really has to be the Turtle , Director is also my girlfriend and not only has to be the turtle but has to have a certain look

[skip coyne]

Thanks Yonak we do have someone with a bandsaw who cuts them for us in a pinch , we ust cant get her to do that quantity problem is volenteers come and go and we sould really need a few willing to spend the time to learn it .

[skip coyne]

Sorry, double post I'm having some problems getting used to responding here

[skip coyne]

If you could "open up" the spacing between the body & the legs a little bit you could make an aluminum, or even plywood template so that when using a router guide bushing against the template they could route the profile quickly & they would be duplicates.

I had thought of that but the director wants the look I posted no larger spaces

[Art Mann]

It would certainly be easy to cut this thing out in quantity on my CNC router. Maybe you can find someone local who will do it that way as a charity project.

[Mel Fulks]

Sometimes the "director" is the ONLY PAID employee in these charity organizations. Sounds like you would like someone who is a volunteer to make those ugly signs. I'm betting if someone is injured you will have problems ...and no director to address them. Is there anyone reading this thread who thinks the redundant turtle will bring in more money than one turtle on a rectangular sign?

[Mel Fulks]

I did not see Skip's reply to my first post until after I made my second. I have pm'd him that and my assurance of no intended insult. Mel

[skip coyne]

no offenses taken Mel , I know everyone is trying to be helpful and I appreciate all input

[Marion Smith]

I make scrollsaw Christmas ornaments for our grandchildren, maybe four or five different ones for each grandchild. So, what I do is stack the 1/4" stock, Brad nail together in waste areas, cut once and I have enough for all the kids. I'd stack 15 of these together, and try the pattern with a 1/4" or 1/8" bandsaw blade. If that works, you really only have to cut out ten of them!