Ok Guys here are the first of the pictures from the project mentioned in this thread http://www.sawmillcreek.org/showthread.php?t=40360 (which turned out to be far more controversial than I expected.
- First a picture of part of the building showing the construction of the corners (its only been up a week and already it is covered in building dust and cob-webs. One of the penalties of living in the English Countryside
.)
- Now a picture showing how these are formed.
You will see that there is a need to cut 2 rebates, one in the top and one in the bottom, so they interlock.
- Here is the jig I made up to accommodate the placing of 29 lengths of timber side by side to cut the rebates with the router. (I set it for 29 as that is how many logs are used for a complete side wall of the building.)
For the purpose of taking the pictures I have used 2 short lengths spaced with a length of timber as these are the only 2 I had left after completing the first part of the project. The rest are now up as you see in Picture 1. The original logs were 20 feet long and supported at the other end using trestles.
- Now the setting up of the EZ Router system.
I am using a Trend 1/2 inch router. I could have used the 1/4 inch, as the system can take any router, but for this part of the job I did not think the 1/4 inch was man enough.
So, with the router mounted on the plate the first thing I did was set the rail on the Jig. You will see that the jig has 2 Plywood placing fillets so that each time I removed and replaced the rail to change the planks I knew it was going back in exactly the same place each time. The clamps being under the rail I was able to clamp the guide easily without interfering with the work space.
- Next I placed the router on the rails and set the limit stops so that the first cut was half the width of the cut required when in the rear position,
and the second stop allowed me to move the router forward to cut the second half of the rebate. (The rebate is 40mm wide and I could only get a 20mm straight cutter that was long enough to reach the required depth.) (mm - sorry I'm in the UK and we no longer use inches).
Having Now set the stops, I position the router slide on the back stop and set the depth and make my first pass along the length of the rail cutting 29 boards at once.
I reset the depth and took my second pass to the final depth.
I then moved the router slide forward and took my first then second pass.
The top rebate on the first set of boards was now done .
I removed the guide rail, and turned the logs up side down and repeated the process for the bottom rebate.
Here's the finished product. (Note the bevel ends were done afterwards with the same jig but using the saw attachment with the saw set at 45 degrees).
I repeated this 3 more times for the other logs to form the other 3 walls.
In all the procedure to do all 29 logs for the first wall - with both rebates - took 15 minutes. It was effortless and easily and all the logs for the four walls was done in just over an hour (including having a cup of tea).
I have not had time to take the pictures of the router being used to cut the T@G shown on the top of the logs in the picture, but this was a similar procedure except this time routing the full length of log laying flat on a long 20 foot makeshift table. I will add those details in the next few days - if I can find the time to set it up for some shots.
Anyway, I hope this has been useful and if there is anything which is not clear - let me know.
Maybe my next project will be - 'A New Garage - The video'.
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Originally Posted by Peter West
