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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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