3 Attachment(s)
"Fusion" Scale Blanks: How-To
First I'd like to give some credit to Buddel who was the first to do this.
This recipe makes 2 sets of blanks, mirror images of each other. I prefer this method because it doesn't waste wood.
- Buy or make 1/8" stock from two woods you'd like to use.
- Make 2 pieces of each about 1-1/2" x 6" (4 pieces total)
- Use double sided tape or rubber cement to stick all 4 pieces together in a sandwich. Placing the harder/tougher of the woods on the outside will reduce the possibility of blowouts from the saw later, otherwise order does not matter.
- On a Scroll Saw with the finest blade you can find, cut your pattern. The patterns you can do and the final snugness of the fit is entirely dependant on the blade selected.
- Once the pattern is cut, carefully disassemble the pattern and lay it out.
- Glue the pattern together. The type of glue you use will depend on the intended finishing products. For CA or varnish (polyurethane) I find carpenter's glue works well. For oil or shellac, you might consider using CA or epoxy based adhesive (just be sure not to get too much on the face of the blanks of the finish may not adhere correctly)
- Using an orbital sander, sand the blanks until they are flat and the pattern is flush.
- Continue on to make your scales
Notes:
- Use a medium-low speed on the scroll saw for harder wood or thicker blanks. This step is time consuming and rushing it can cause scorching or the blade could break. Some experience on the scroll saw is an asset.
- Small gaps in the glue line can be filled with home-made plastic wood. Mix a small amount of the sawdust from the scroll saw (already a 50/50 mix of the 2 woods) with carpenter's glue until a wet paste is formed. Fill the gaps with this paste by rubbing it in with your thumb. Once filled, rub off the excess with a damp cloth.
- Delicate woods or thin blanks are best employed with a liner (brass works well). Apply the liner onto the blanks after they are sanded flat.
Pics attached are of blanks made this way with Rosewood and Curly Maple: