Once the initial parts for the sink were glued up (the large U shape sections), it was time to make the actual components. Ideally, I wouldn’t have had to take the previous step, but I am working with a limited stock size, partly as a bit of an exercise, partly because I have the timber, and don’t feel like buying something else. The redgum is being salvaged from the ugliest, oldest sleeper you would have seen in a long time. Always surprising just how much good timber is hidden behind a rough façade.
Creating the sink template
To cut the individual sections out, I created a template from MDF. It is easy to draw up and shape to the required profile.
Template attached
In this case, I didn’t have to worry about screw holes, so it was easier and less problematic to use screws (Kreg square drive). You may wonder about the amount of timber wasted here inside the sink. It won’t be going to waste, as I intend to use this again in the same way to produce some other (as yet undecided) kitchen appliances.
Bandsawing around the template
To remove the bulk of the material, the bandsaw works exceptionally well. Cutting near to the template reduces the load on the pattern copying router bit.
Routing to shape
Over to the router table, and with a pattern bit (a straight cutter with a bearing on top), each piece of the sink is routed to shape. (The photo above has the piece upside down)
Glued and clamped
Next, each piece is glued and clamped together to form the body of the sink. The ends have also been cut using the same template, but obviously only the outside is cut and routed.
Spindle Sanding
The spindle sander is next, and is the perfect tool for this job. It may not get the full depth, but flipping the workpiece over a few times keeps things pretty even.
Fine sanding
The size of the sink just allowed me to get the ETS150 inside, but it isn’t ideal for sanding around corners…..except I have a soft sanding pad (from Ideal Tools). This has hooks on one side, and loops on the other, so it acts as a spacer between the original sanding pad and the sandpaper. With this, it is really easy to sand all sorts of concave and convex profiles.
Soft sanding pad
This is the soft sanding pad – a very useful addition for the ROS.
***Update: it is called an interface pad, and can be found here
Attaching the sides
With the inside done, the sides of the sink can be attached. This (and the next image) were actually photographed before the glueup, but it gives you the idea.
Laminated sink
So that is how I make the laminated sink, still ensuring that the entire project can be made from timber. Not sure if I will be able to maintain that ideal for the entire project, but I am still working towards it. Very pleased I used contrasting timber this time – might as well make a feature of the laminations!
Filed under: Timber, Wooden Toys Tagged: Bandsaw, ETS, Festool, Lumber, Router, Router Table, Sink, Template 
