Project: "Making a Big Wall Clock"

     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.

   Using a carpenters square that is against the center pin (arrow), I can draw the first radial line.

   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.

   Now I have all my radial lines, and they look good.

     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.

   I use the same marker to draw two circles that will represent the borders for the "minute tick marks."

   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.

     

   I have found a scrap of 1/4" plywood that I will use to make the template.

   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.

    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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