Thread: Step by step creation of a fancy lined wedge

So, many of you saw that Filly I posted in Gallery earlier today... I said I'd make a workshop thread for process of making the wedge.

Ok, well, first of all, I skipped the obvious parts -- tracing out a rough shape, cutting out the rough shape from the stock material. I'm using 1/8" thick Red G-10, and .011" gray G-10 for this wedge.

I also skipped the part where I sanded down the wedge to make it wedgie

We'll pick up here:

I've taken my cut out pieces, drilled holes in all of them. I marked the location of the holes by holding up the rough cut wedge to my scales, and marking them through the holes on the scales, that way they lined up. My next step, is to temporarily bolt the middle Red G-10 and the two liner pieces together, like so:





The important part here is that your red piece will hang out of your scales, and your liners hang off of your main wedge... Trimming everything up later is easy.

So, the first thing I do, and the reason I temporarily bolted them together, is that on the razor-side of the wedge, I need to match up the liner lengths with the wedge, and ensure they are totally flush together.

I went to my disc sander, and I went from the pics above, to this:



As you can see, the razor side is all flush up. I then take some 400grit paper, and 800 grit paper to this one surface, and then quickly buff it so that it is "finished" (just the one side!)

Next step -- I disassemble my bolts, and I take JUST the liners -- remember, on this razor, my liners need to be flush with the scales, and the wedge will stick out, so, i need to profile the liners identicle to the scales. I bolt the two liners between the two scales, and then file out the center:



I'm not worried about the excess on the tops and bottoms, and they can be trimmed later, along with the red part.

Then, I run sandpaper in there through some grits wrapped around the file in order to get it buffed up and polished:



So, I'm left with this -- I also take the time here to buff up what will be the visible portion of the red G-10



The next step is to pin!



(one more post...)

Now, you'll notice why I took the time in previous steps to "finish" those filed surfaces -- as soon as i pin, I can no longer get to them to sand them out and buff.



now, I take the entire scale, totally pinned up to the belt sander:



From there, I go to 320, 400, 800, 1500 grit hand sanding, and then do the final buff:

Awesome work Brad and I added it to the Workshop Sticky too

Thanks for taking the time Brother

Mind if I try this on one of mine Brad? Also, thanks for putting this down in a thread. I had it partially figured out in my head, but the details were a little fuzzy. Lol. I didn't know how you were going to hold everything together while you were working on it. What size bolts are those?

absolutely, go for it. its an interesting look!

The bolts are 0-80 stainless. I have a local hardware store that carries them (its a Do it best store). You could use microfasteners bolts, too.

Oooooo.........we have a do it best here too! It's my favorite hardware store because the employees don't give me blank stares when I ask for furniture epoxy or ball pein hammers. And I can even walk the length of the store in 45 seconds! Guess who's making a trip to the hardware store tomorrow!?

Thanks Brad! Very creative and gives me more directions to go in. I appreciate you posting this!

Fantastic. Thanks for the step by step details, although I could never in a million years be able to do what You have done.

That looks absolutely amazing!

Thanks for breaking it down!