thanks, Jesse!
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A few more words on finishing the sump for Padrino and Veloboy. Once everything was done, the last effort is router the edges and then cutting out the eurobrace. First things first, ALWAYS wear proper PPE. Ear plugs and eye protection are a must.
Having enjoyed ER trips for catching table saw kickback in the face, and having suffered from excessive dB related tinnitus in the past, I don't do anything with power tools without first plugging up my ears and covering the peepers. Of course, this presents scenarios of needing new underoos when your wife sneaks up on you to offer lunch, but it's certainly worth it. For my projects, I've been using this bosch router with great success. A 3/8" flush bit works perfectly.
The first trick is to take off any overlap along the edges, as you need a flush edge before cutting out the eurobrace. I just run the router along the edges at a slow-ish speed to cut it cleanly. When done, you'll have two things. First, a fresh dusting of snow.
And second, a nice, smooth sump.
Next come the part which requires thought. You'll need to determine your bracing thickness, and I just went with an easy 2.5" since it's the same radius from the router bit to the edge of my router base. This is probably a bit on the small side, but since this is just a sump I wasnt worried about over-bolstering the eurobrace. I marked the lines for the eurobrace and crossbrace, then I simply clamped a board to the end of the sump. I use this board as a fence, running my router along the board and stopping when I get to my marked lines. (you'll have to drill a hole to get the router started, or course).
I do the long cuts first, but it doesnt really matter. Once those were done, I brought out the clamp fence and basically did the same thing for the other cuts. For the cross brace, again it's just 2.5", otherwise I would have had to make a more specific determination of where to put the clamp fence.
When you're done, there's nothing more than perpetual cleanup of acrylic chips!
NOTES:
- Always run the router so that if it comes off the fence it moves towards the middle of the sump and it can't ruin the brace
- When cutting the eurobrace, never allow the acrylic parts to fall into the sump; they will break off before the cut is finished, and you'll end up breaking the brace.
- Do this in an open area that's easy to sweep up, as the acrylic chips are really a pain.