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Ken Martin

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Reply with quote  #1 
Hello Friends

I wanted to share an idea with you that is not new exactly, but is new to me.
We have all heard and used tape, and or nails to hold our stacks together when we are stack cutting multiple parts.

A friend, I have found to be a master at Scroll Saw stack cutting, Ned and his wife Bonnie, use Hot Melt glue for holding their stacks together.

I started doing this with small pieces, but now I tried it on the 12 Toys of Christmas Tree. The Christmas Tree is 20" by 20" by 14" so it is a big piece to hold together, plus it is an 1"-1/4" thick when holding the three parts of the tree together.
I was not sure if using Hot Melt glue would work on this big a piece.

Step 1:  Getting the blanks ready.
DSC05822_mini.JPG

Step 2:  Tool needed.  Any Hot Glue Gun
DSC05824_mini.JPG 
Step Three:  On the side which would be the bottom of the tree, I only used glue on the sides because I did not want to be removing glue from the bottom of my finished parts. DSC05825_mini.JPG   
Steps Four and Five:  Putting the hot glue on the rest of the sides, did not matter where or how much I put on because these would be the waste pieces.
Photo below shows 6 glue spots.  Turned out to be overkill.
DSC05826_mini.JPG  Photo below shows the uneven side of the three pieces.  I used the glue gun like a caulking gun and ran a bead along the whole edge.  Again overkill, because we learned you don't need that much holding power even on a big piece like this.
DSC05828_mini.JPG 
Photo 6 is the template I made from peel and stick floor tiles.  I always make a template if I even think I will be making another one in the future.  I like to make my templates out of the peel and stick floor tiles because they are easy to store in a file cabinet when I am done with them.
DSC05829_mini.JPG  Because this project was so big, I made the template out of 3 tiles.  A and C fit on one tile, but B and D needed a tile each.  OK because the waste will be used for other smaller templates.

Photo 7 shows the pattern drawn on the bare wood.  This saves tape and is easy to see, and if I used the right blade for the project then cutting an 1"-1/4" thick piece of wood is not a problem.  (Note: at first I did not pick the right blade, which is another story for another day) DSC05830_mini.JPG 
Photo 9 shows the cutting of this template.
DSC05836_mini.JPG  Like I said I started with to small a blade and did not like the results on the first couple of cutout. so I finished the project with a #12 blade.

Photo 10 shows the results of the stack cut and that all three pieces held together great with the Hot Melt glue.
DSC05832_mini.JPG  After these cuts were done I tossed the waist aside while I finished the rest of the cuts and when I looked at them later the Hot Melt glue was still holding the three parts together.

Photos 11 and 12 shows you an exercise in Silly.  The first photo is me trying to do a really neat masking job and trying to save tape.  After 1/2 and hour of messing with this I said; "The heck with this". (maybe not in those exact words)
DSC05838_mini.JPG 
And went to covering the whole thing at one time.  This took 5 minutes.DSC05839_mini.JPG

  Photo 13 shows an easy way to use natures light box.  By holding the piece over the side of the table I could clearly see through the tape, which gave me a great guide for cutting away the unwanted tape.
DSC05840_mini.JPG 
Photo 14 shows my high tec drying rack.  I left the parts on the round turn tables and held them apart with small paint jars, because I do not have the space to spread them out all over the place.
DSC05842_mini.JPG 
Photo 15 is the test fit to see if this tree is going to be OK before it is glued together.
DSC05844_mini.JPG 

Photo 16 is the finished 12 Toys of Christmas Tree.
DSC05848_mini.JPG 

If you followed this I hope the Hot Glue Tip will help out.  Remember you can use this on very small stacks as well as larger projects like the Christmas Tree, because the glue is only on the waste pieces.

Note:  There is some waste pieces left over from this project, and even the cutouts will be used for Martin Motors Cars and a bunch of Martin Motors Mini cars.  Almost all waste pieces will be used.

Thanks


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Kenneth W Martin
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Udie

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Reply with quote  #2 
Ken - What a great tip - thanks for posting. I will definitely do a cut and paste and keep this post in my files. And again, the Christmas tree looks really sharp, I like the white center piece and how it is sandwiched between the coloured pieces. Good job. 
Sdaupanner

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Reply with quote  #3 
That is really looking good and yes the glue is an old tip and I have never tried to use it ..... maybe the next project will have some glue in it.
Don
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Reply with quote  #4 
Ken, it is great to see that you do not throw away the scrap pieces. So many times I have seen woodworkers throw expensive short cuts away, to many people an 18" cut off is a burnable scrap. When you are making toys those scraps can build a whole project. I am a bit obsessive about saving off cuts but they really save money when I am making small items. Today hardwoods or even pine cost a lot of cash, so I try to use every piece that I can.
That is a great looking tree!! I bought the plans but have not been able to build it yet. Currently I am building doll bunk beds for the ministers wife for their grandchildren for Christmas. 4 - bunk beds 14 X 25" mattress size. They have kept me busy the past couple of weeks. Bruce

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Ken Martin

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Reply with quote  #5 
Hi Bruce
   I use or reuse everything I can trying to save money where possible.
Thanks for the nice words about the Tree.
You will like building the 12 Days of Christmas Toys Tree.  It is fun and easy enough for even me.
   Sounds like your are keeping busy with the bunk beds.  That is a great project.

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ctowne

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Reply with quote  #6 
Ken -
Great tip and step by step pictures.  I will definitely try this.  I stack and go through a lot of tape.  I believe this will save some $. 
Cindy
Ken Martin

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Reply with quote  #7 
Cindy
   Another tip:  The hot melt glue holds so well, you need very little to hold it together.
I used to much on the above tree around the edges and had trouble separating the scrap pieces.
A friend showed me when he is stack cutting small things like ornaments and such, it really takes very little hot melt glue to hold things together.
   This is especially great when you are doing a small stack.  I now draw right on the wood because I don't need any tape to lubricate the blade on a small stack.
This also saves time.

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Doc

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Reply with quote  #8 
Handy tip and very cool work Ken [thumb]
The only tip I would add about using a hot glue gun is
'Don't be tempted to use a finger to smooth out the lumps - it will burn your fingers'
Don't ask me how I know this [frown]

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Ken Martin

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Reply with quote  #9 
Thanks Doc
So glad to see you are still out there.  You always have great ideas.

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Kenneth W Martin
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