Scroll Saw Name Chain

Pattern

Making some name chains for four of my young friends in the neighborhood.

Looked around Internet and zeroed in on a pattern style that I liked...

Using Word, I created a name in large Cooper Black font (~200).

This filled the page in landscape orientation

Then on the advanced tab of the font selection, I played around with settings until the letter overlap looked about right for scroll saw work...

Spacing = Condensed > By = 13 points
Then on the Format Text Effects tab...
for a nice working template look...
Text Fill = No Fill
Text Outline = Solid Line
Wood Prep
I used a thin blank of African padauk...left over from the jewelry cabinet.
Surfaced with a bevel up smoother...
Squared with a jack plane...
Scroll Work

Scroll saw blade selections...

for tight outer cuts...Olsen 5R reverse skip tooth

For inner cuts, Olsen #2 spiral tooth,
Downsized the names, printed the templates...fit them to the  wood blank...glued on with 3m #45 spray adhesive
 The spiral blade required a 3/64 inch pilot hole.
CTD test for blade and bit selections
After the full template is cut out...

The template paper removed...Goo Gone...
Sanding, Rasping and Finishing
For the flat surface sanding I used 220x and 320x grits adhered to a granite slab...edge sanding was done with a variety of grits with small backing pieces

For shape refinement I used wide variety of Auriou rasps and Auriou or Ajax Plinky rifflers.

A great finishing cutter was a Murphy knife with a long cutting blade.

Amber shellac...brushed onto inner and outer edges......padded onto flat surfaces.
Drilled a 1/16 inch hole for eye hook...the bit was too small to fit in the drill press.

At first I designed these to have the hook in the first letter of the name and the unit would be vertical...
...later changed to placing hook to hold the name horizontally.
I experimented with options to hold a smaller bit in the drill press...I put the small bit into a pin vise and then secured that in the drill press chuck.


Reasonably successful...in particular, it made the hole drilling easier to keep aligned vertically.


 

 

 

 

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