Tool Guide - Ray's Wood Signs

Tool up Suggestions

1. Routers: Large for shape edges, background material removal and creating patterns and templates
   • Dewalt DW618, DW616
2. Routers: Small for carving
   • Dewalt DWP611 (Porter Cable 450)
   • Dewalt DCW600B 20V Brushless
   • Bosch Colt PR10E, PR20E 1.0 HP
   • Bosch GKF125CEN Colt 1.25 HP
   • Makita RT0701C 1-1/4 HP
   • Porter-Cable 690LR 11-Amp
   • Rigid 2401
3. Modify router bases by opening up the back
   • make a 2" hole in the back 2" from the bottom
   • Leaving the base plate intact, saw from the bottom up to the edges of the hole to extend the hole to the base
4. Base plates for routers
   • Clear base plate
   • oval 5 x 7.5 (regular small signs)
   • raised side handles
   • 12 x 12 (straddles large gaps)
5. Small compressor, hose and nozzles
6. Chop or circular saw
7. Table saw
8. Band saw
9. Angle grinder - sidewinder
10. Circular and belt sander combo
11. Belt sander OR Disc sander AND
12. Palm orbital sander
13. Drill & bits
14. Shop Vacuum /air blower
15. Compressor
16. Heat gun
17. Critter Sprayer 22032 118SG Siphon
18. Dremmel or rotary tool for extreme fine detail, 1/8 or 5/16 bits and pattern cleanup
19. Collet and bit sets for 1/8, 5/16 and 1/4 shanks
20. Router base plates and inserts
21. Wrenches for collets
22. A good, solid bench with vise & dogs
23. Good overhead lighting
24. Magnifier head strap
25. Ear protection
26. Safety glasses / goggles
27. Safety face shield
28. Respirator, face mask
29. Sanding blocks and sanding sticks
30. Kutzall shaping discs
31. Belt cleaner sticks
32. Diamond 300 - 600 grit stones
33. Layout tools (ruler, yardstick, tape measure)
34. Bench cookies / board covered in rubberized drawer liner
35. Moisture meter
36. Heavy nylon bristle brush
37. Carving tool and X-Acto knife
38. Magnifier head band or glasses to 5x
39. Safety glasses, hat
40. Portable goose neck lamp

Helper Tools

1. Foldable lazy susan for spraying
2. Jigs for corner cut out (2, 3, 4") jigs
3. Reciprocating saw - sawzall
4. Grinders, bench and sidewinder
5. Anti skid drawer liner or mats
6. Sanding board to hold tight
7. Sanding sponge
8. Paint standoffs or carpet strips

Laser / CNC

1. Laser Pecker
2. Atomstack
3. BobsCNC
4. FoxAlien
5. Genmitsu
6. Nextwave cnc
7. SainSmart
8. Shark
9. CNC Tool Specs
10. CNC 2 Tool Specs

Cleaning

Vid 73

1. Keeping the resins off of the bit reduces heat and further build up:
2. Clean bits will last 3 - 4 times longer between sharpenings
3. Use a dremmel brass wheel to polish the flutes after each use and especially before sharpening.

Sharpening

vids 8, 164, LTS8/27/17, Cofee & Questions 12/13/17 (dull bits)

1. Keep cutters sharp
2. Sharpness test: Use your fingernail and rub the bit against the surface. If it cuts / shaves or it drags it is sharp enough. If it is smooth it is dull and needs sharpening.
3. Carbide cutters = diamond wheel
4. Use 600 grit diamond jewelry wheel
Grinding wheel available here

Grind at the center of the wheel or slightly below to give clearance.

5. Profile bit

   Sharpening shortens the bit = wider cut in wood

   • 2 flute
   • The bit is 15 deg on the side with 45 deg tip
   • Sharpen flat side, not profile
   • Sharpen the 45 tip first, then the 15. Barely touch and then turn it.
   • Do the 15 degree by dragging across the wheel and turn it.
6. 60 & 90 Degree
   • Use a very light touch at exactly the center of the wheel
   • Move side to side until a new surface on the cutting edge is formed
   • Roll out very slightly as the grind is finished to create clearance for the cutting edge.

   Clearance is the same as for a drill bit, @ 5 - 6 degrees to let the chips clear away from the cut

   Not enough that it catches the other flute

   • Repeat on all 3 flutes
7. Chamfer bit
   • Remove bearing and shank
   • Lay flat 90 deg and roll off
   • Do the same amount on all flutes
   • Diamond fine hone

Tool Tips

1. Re-sharpened bits = fatter, wider cut
2. Roto tool might not = die grinder. Power carving may wear out the smaller tool. Die grinder is 1/4 inch collet.
3. Use gasoline or Gunk Engine degreaser for cleaning ink and paint build up on nozzles, wood letters & patterns
4. Use primer - not paint. Paint has carriers that
   • gum up sanding discs and belts
   • causes bleeding through grain absorption

Carving bits

A small brass brush will help bits last longer

1. Angle bits:
   • Can get into tight corners
   • Can be lifted up during the cut to create finer lines at line ends and sharp corners
   • Can be lifted out easier without damaging the sides of the cuts
   • Can be sharpened
   • 1/4 shank bits
   • Profile bit 15 deg (tip is 45 deg)
   • Cove, roundover or 45 deg chamfer
   • 60 deg v-groove
   • 90 deg v-groove
   • fine pattern bit (SC50 Whiteside) OR
   • carving liner

Bits and supplies can be purchased from the Make a wood sign site

All carving bits are cut at an angle except the spiral bits.

2. Spiral bits:
   • Use 1/4 shanks for all signs
   • Carbide straight bits will snap if stressed or horizontal pressure
   • 1/8 and 1/4 upcut and downcut
   • Cut flat, creating flat-bottom carvings
   • Use upcut 1/8 and 1/4

Spiral bits Pros and Cons

3. Pros:
   • Cuts all material very well
   • Cuts flat for outset and inset
   • Takes out much more material
   • Sharper lines with steep (90 deg)edges
   • Great in tight spots
4. Cons:
   • Cuts effortless in soft material so it needs very careful control
   • Going in and out of one spot needs to be exact
   • More likely for the letter to chip during sanding due to sharp angles
   • Easy to over spray
   • Sanding dips on the surface can chip out or change sharp edges
   • Can't be sharpened
5. Rasps / power carving

   Kutzall sells these

   • Rasp bits; nose, ball and flame
   • Extreme shaping discs (4 1/2) for angle grinders

Because of the bit angles (<90 degrees), all angle bits leave a groove in the wood.