I am using black limba boards that are 24 inches long for my hippopotamus Christmas tree ornament project. However, 24 inches is too long to cut on my Excalibur EX-21 scroll saw. I needed to separate the patterns, but there wasn't enough space between the patterns to use my miter saw. Smaller pieces are easier to cut on my scroll saw and drill holes for the eyes, so I use my scroll saw for the cross-cutting.
With the patterns applied, step two in my 275 Hippo Christmas tree ornaments project is trimming the wood to size. Black limba is expensive, so I carefully ripped one-inch strips from the edge. While one-inch-wide strips alone are of limited use, wood glue and clamps can effectively join them together. For example, if I face glue two of the strips together, I will get a 1x1-inch square. I can compound cut square pieces on my scroll saw into small birdhouse ornaments or turn them on my Shopsmith lathe. Five-inch-wide boards would have been the perfect width for this project. However, it was not available in five-inch widths.
I used my Shopsmith table saw with a thin kerf 7.25-inch Freud blade and a zero clearance insert to do the cutting. I also used two Microjig GRR-RIPPER push blocks to feed the wood through the saw.
I applied the pattern labels to the black limba boards, placing three labels on each board. Each board accommodates 27 hippos, and I have also started on a part of another board. This setup will yield a total of 275 hippos, plus four extras. I always aim to create some additional pieces in case something goes wrong. If all the hippos turn out well, I will ship the extras to the customer.
I wanted to crosscut between the labels with my miter saw, but I couldn't get the sticky labels aligned straight enough to ensure clearance across the entire area. In hindsight, I should have placed one label on each end and one label in the center. This arrangement would have given me enough room to use the miter saw.
As the holiday season approaches, I've been busy crafting some unique decorations for my customers. This year, I have an exciting custom order for 275 hippopotamus Christmas ornaments made from 1/2-inch black limba wood. The unique texture and rich color of this African wood will make each ornament a standout piece.
To bring my vision to life, I rely on Inkscape, an open-source vector graphics editor that I use on my Linux Mint operating system. Inkscape allows me to create precise patterns that fit the requirements of my project.
I am using half-sheet labels for this project. They fit the six-inch-wide wood, and this approach eliminates the need for messy spray adhesive, allowing me to work more efficiently and help keep my workspace clean.
I spent some time trimming the labels to maximize the wood's use. This practice not only helps me reduce costs but also minimizes waste—a philosophy I strive to incorporate into all my projects.
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For woodworkers and DIY enthusiasts! If you're like me, there's nothing quite as satisfying as turning a simple piece of wood into something functional and beautiful. Today, I'm sharing how I make a pair of intricate fretwork shelves made from 1/4-inch-thick oak, all cut using my scroll saw. These little gems are perfect for displaying small items. The process was a mix of precision cutting, careful assembly, and a bit of patience while waiting for the finish to dry. I'll walk you through the steps, complete with photos from my workshop. Let's dive in!
Materials and Tools
Here's a quick rundown of what I used:
Preparing and Cutting the Pieces
I started by printing out my fretwork pattern and adhering it to the oak using spray adhesive. The design features symmetrical curves and cutouts that give the shelves their airy, decorative look. With the pattern in place, it was time to fire up the scroll saw.
The key here is slow and steady – scroll sawing intricate designs like this requires a light touch to avoid blade breakage or splintering the wood. I cut out the main shelf brackets first, following the lines meticulously. Drill small pilot holes for interior cutouts for threading the blade.
Once the brackets were free, I moved on to the smaller decorative elements and the shelf platforms themselves. The collage shows the pieces laid out after they were cut.
Assembly and Gluing
With all the parts cut, it was time for assembly. I dry-fitted everything first to ensure a snug fit, making minor adjustments with sandpaper where needed. Then, I applied wood glue to the joints – nothing fancy, just good old Titebond.
Clamping is crucial for strong bonds, especially with thin material like this. The images capture the gluing process: orange clamps holding the brackets together while the glue sets. Let it cure for at least an hour, or overnight if you can wait (patience is a woodworker's best friend).
Finishing Touches
After unclamping, I gave everything a thorough sanding to smooth out any rough edges from the saw. Then, it was time to finish. I opted for a couple of coats of shellac.
The final photos in the collage show the completed shelves hanging up, drying in the workshop. They're lightweight yet sturdy, with a small ledge at the bottom for stability. No hangers are required. A tiny nail or pin will do.
The Finished Product
And there you have it – a pair of fretwork shelves ready to grace any wall! Total time? About 4-5 hours spread over a couple of days, including drying time.
My Etsy Shop
Avoid purchasing a saw that uses pinned blades. You will regret it.
For me, the ease of use and speed of blade changes are paramount.
My saws:
What I appreciate about these saws is that when they are properly aligned, no tension adjustment is necessary. You flip a lever to change the blade, then flip it back into place. This design tilts the blade instead of the table, which makes angled cuts easier to achieve. I have access to parts for both of these saws and have completely rebuilt the Excalibur EX-21.
The Harbor Freight Bauer scroll saw operates similarly to the EX-21/Pegas saws. The lift mechanism is different. It is the lowest-cost saw of all the saws mentioned here. Harbor Freight's in-store warranty is as good as it gets. If it breaks during the warranty period, you can return it to the store and they will provide you with a replacement. If I were in need of a new saw, I would give this one serious consideration.
The Seyco saws are quite similar, but they feature a larger table and a
different tilt mechanism. However, I'm not fond of the table on the Seyco saws. Seyco saws have awesome support. They also support Excalibur and Pegas saws with parts available for both.
Other Scroll Saws
