Day 3, Saturday 8 June, 2013 1 hr 46 min, Total 4 hr 12 min - Lower section of back

Today I will start on the lower back piece.  As I mentioned earlier, the plan for the Worthington clock was scanned into the computer in sections off of the plans.  The plans were printed on large sheets of paper that I didn't want to cut up.

The above shot shows the lower section of the back panel in adobe photo shop.  The plan will be printed out and attached to the wood so we can start cutting.  The plan only calls for 1 of these pieces to be made.

The pattern printed out on a 8.5'' x 11" sheet of paper.

Used some scissors to cut off the excess.

Cut a piece of 1/4" baltic birch plywood.

I use this Fast Tack 87 to glue the pattern to the wood.  The instructions on the "Fast Tack" say to only spray one side if it is going to be stuck on temporary.

Here is a shot of the pattern glued to the wood.  The wood was sanded before gluing the pattern on.

The next step is to drill holes to thread the blade for the inside cuts.  This particular piece has 28 inside cuts, so 28 holes need to be drilled.

Once the holes are drilled, the back is sanded again so it will lay flat on the table of the scroll saw.

I always start on the inside cuts first.

Here all of the inside cuts for this piece have been made.  Now I have to cut around the outside of this part.

The outside has been cut out, now its time to remove the pattern.

The heat gun makes it easy to remove the pattern from the wood.  It melts the glue and allows the pattern to be removed with out any problems.

After the pattern is removed, there is still glue on the wood.  It is removed using a pro-stick, a Pro-Stik is used to clean wood belt sanders, disc sanders etc.  Here you can see the glue balling up.  It removes the glue from the wood with out to much work.

Once the glue is removed, the part is sanded with 120 grit sandpaper.

Here is the completed part.

Here is how this part fits with the main back of the clock.