The Defiants - InDIYana 2019 Build

[KEtheredge87]

Thanks John, I think I understand how your jig works. Just a simple flat MDF sled with two angled stops fixed to it... Cut one side, rotate the baffle to the second stop, and cut the second side. I'm having trouble thinking about that method for my baffles. My saw will tilt 30 deg to the left, but I have two facets on each side that cut in different directions. The top facets cut from baffle center and move toward the sides, while the bottom facets go from sides toward the center. I think I'd still have to move the setup to the other side of my blade, but the the blade angle is wrong. Am I missing something? Sent from my Pixel 2 XL using Tapatalk

[a4eaudio]

Am I missing something?

I've been asking myself this question. I have seen in the past that people have built a sled for facets. Why not just use a circular saw set at X-degrees and use a guide?
Is it just the precision you gain from the sled, or are there other reasons also?
I don't really get how the sleds work from still-pictures, so hopefully you will post another nice YouTube video for us non-engineers!

[KEtheredge87]

I've been asking myself this question. I have seen in the past that people have built a sled for facets. Why not just use a circular saw set at X-degrees and use a guide?
Is it just the precision you gain from the sled, or are there other reasons also?
I don't really get how the sleds work from still-pictures, so hopefully you will post another nice YouTube video for us non-engineers!

Good idea I'll video the process on that one too when I get there. There are actually a few methods I considered for making these facets. In no particular order:

1) Roughing the facets in with a chisel --> hand plane --> final surface by sanding (supposedly not that difficult. Troels Gravesen discusses this on his website's Tips and Tricks page)
2) circular saw with guide
3) table saw sled with taper jig

I wasn't confident that I would personally do well with the circular saw at an angle method, and further I wasn't sure I could set the angle on my circular saw as accurately as I would want. I tend to overthink, and overestimate the difficulty of a task before I try it... so I may be wrong about my potential success (or lack thereof) with this method.

I like the table saw sled method because I feel more confident in my ability to control the angles, and really lock down the adjustable parts that will guide the sled (table saw fence, taper jig angle setting, facet sled construction).

The idea of the sled is all about holding the work. I will keep the sawblade at 90 degrees (straight up) and use the taper jig to set the 7 degree miter angle while the facet sled has it's face at 60 degrees to the table. This (when pushed into a 90 deg saw blade) will result in a 30 degree bevel angle on the workpiece. Once I have my tablesaw fence set the appropriate distance from the blade, all I need to do is safely push the whole sled and taper jig forward into the cut. The taper jig rides against the fence which controls my position in the X direction (left / right) and the saw's table fixes my workpiece against any rotation or movement in the Z direction (up / down as in floating above the table or sinking into the table). That just leaves me to control the speed at which I feed the baffle through the sawblade in the Y direction (forward and backward).

There's a lot of engineer-ey words there to describe what's going on... but as usual this operation is 99% setup, and 1% cut. You'll see!

Thanks for following along!

[tomzarbo]

I'm looking forward to seeing a video of this happen as well.

I know how I'd do it... I would draw all the angle lines on the cabinet and rough cut them on the band saw probably, or whatever would work to hog out the bulk of material... reciprocating saw and a steady hand?

Then, I would go to the big 6" stationary belt sander and get real close to the lines with that, then finish up with a large sanding block, like my 2x2 clampable sanding block and move the cabinet over it until I reached the drawn line...…

…. but that is total butchery, I know. I'm almost embarrassed to type it, but I do believe that's how I would do it at this point because I don't know how else to do it. I have an awful time with figuring angles out if it's not something that I can understand in my head visually. This would loose me for sure.

It will be cool to see how it's supposed to be done. Keith, I'm glad you plan to document what you did, and maybe a little of the 'why' for all posterity. I know if I were doing it the way I outlined, I'd be wasting a lot of 'practice' MDF.


Stuff like this makes me realize why you CNC guys love them so much.

TomZ

[Wolf]

JohnH- Thank you for your jig drawing! For some reason, I always thought you needed the blade to tilt both ways, but your jig makes the blade the same in both cases. That's very novel!

Might have to add that to the arsenal...

Wolf

[jhollander]

Here's 2-d pic of a sled for one side tilt table saw arbor. This assumes the facets are symmetrical and you mount the baffles on a box. Whatever method you choose the facets will need to be tuned up. I used my block plane, #6 plane and sandpaper on MDF board to get the shapes closer.

Note, I locked my box down on the jig and did one pass without moving the fence. In retrospect I should have added a fence stop and then moved the fence up to the final dimension while measuring the facet flats at the top ends

[KEtheredge87]

Big News! The facet cuts are complete!!!

I made another YouTube video to describe the process in detail, so I hope it helps people.

Here's a few pictures for those less YouTube-inclined!



YouTube Video:

Here's the Audio from 11:20 - 12:20... Apparently YouTube thinks I sound like a Korean song???
(I got a copyright claim from the Recording Industry Association of Korea)
https://drive.google.com/open?id=1Zw...kpUV-C6xIFLD4H

[dkalsi]

Keith - Super Impressive!!!!!! Sent from my iPhone using Tapatalk

[KEtheredge87]

Yup... I'm a Korean Song alright!

[Kevin K.]

Yup... I'm a Korean Song alright!

You didn't have "Gangnam style" playing in the background did you? Are they saying there's a match between 11:30 and 12:20 on your video? If so, I wonder if you could edit that portion and get it to pass, Maybe just a tad slower or faster to avoid the detection.

[tomzarbo]

Yup... I'm a Korean Song alright!

Not to pile on... but I've always thought that.


Weird!

But then again I'll be talking with Eileen and the next thing we know, Google assistant is saying something to us that has not one thing to do with anything we were even talking about.

Glad the facets came out great, I'll check out the video.

TomZ

[KEtheredge87]

You didn't have "Gangnam style" playing in the background did you? Are they saying there's a match between 11:30 and 12:20 on your video? If so, I wonder if you could edit that portion and get it to pass, Maybe just a tad slower or faster to avoid the detection.

Haha... Gangnam Style is my favorite Korean song! ...also happens to be the only Korean song I know You're seeing things correctly though, YouTube was saying 11:30 to 12:20 contained the supposedly copyright identified stuff. I'm not totally satisfied with YouTube's approach as well... Their little "dispute form" just makes me swear that I own the content in the video, then the copyright holder (NOT YouTube) has to review and approve my dispute within 30 days. So it sounds like my audio will be quarantined for a month while someone in Korea has to watch my speaker building video? I hope they at least learn something! On my end I could probably try to edit the audio and make it "different" but I'd be guessing as to what really attracted YouTube's algorithm in the first place. We'll see if I'm still irked about it tomorrow.

Not to pile on... but I've always thought that.


Weird!

But then again I'll be talking with Eileen and the next thing we know, Google assistant is saying something to us that has not one thing to do with anything we were even talking about.

Glad the facets came out great, I'll check out the video.

TomZ

Aww come on Tom! Piling on is where the fun is! All the cool kids are doing it

Maybe I give "Big Brother" too much credit, but I refuse to have an Amazon Alexa or Google Home in my house. I'm sure my smartphone and laptop are already spying on me... but I don't think they are listening to my every word.

[xmax]

"I'm sure my smartphone and laptop are already spying on me... but I don't think they are listening to my every word."
If you have FB messenger installed they kinda are.

[KEtheredge87]

"I'm sure my smartphone and laptop are already spying on me... but I don't think they are listening to my every word."
If you have FB messenger installed they kinda are.

Thanks for the tip... Just turned that app permission OFF!!!

[Kevin K.]

BTW Keith, I forgot to mention in my earlier comment, nice job on the facets, it looks like they turned out perfect. Did the taper jig come with the Saw-Stop, or did you pick that up somewhere else, I need one.