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Custom Template Place
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Will S
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Joined: 04 Jun 2007
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Location: Virginia

PostPosted: Tue Mar 08, 2011 4:06 pm    Post subject: Custom Template Place Reply with quote

I'm not that great cutting templates accurately on a band saw, so I've been looking around for a while at various alternatives.
I needed to make a set of templates recently that I could hot cut against. I looked at a lot of materials, and eventually found that hardboard does pretty well and isn't nearly as expensive as aluminum. If the soldering iron I use rests in one spot for long it does start to burn a bit, but if I move at a decent speed there's no real damage to the templates, even at the slow speeds required for cutting multiple layers of dacron.

I found this place that does custom pieces - http://www.bigbluesaw.com/

Since I've got my templates in .dxf format already, it was easy to upload and get an online quote.



All the pieces are very nicely laser cut and everything fits absolutely perfectly. I'm quite happy with it Very Happy

So yeah just thought some of y'all might find that interesting. I also ordered some templates for more generic stuff, like the leading edge cutouts in my sport kites.
They do have various plastics available as well, so if you want to use them as a template for cold cutting with a rotary cutter that could work well too.
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shamrok



Joined: 20 Dec 2004
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PostPosted: Tue Mar 08, 2011 5:23 pm    Post subject: Reply with quote

Good stuff. Thanks, Will.
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robkite



Joined: 30 Apr 2004
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Location: Lacey, WA

PostPosted: Tue Mar 08, 2011 5:46 pm    Post subject: Reply with quote

John Freeman had Lindsey at Phantom Star designs do the templates for his class kites. Lindsey has a CNC router that he uses for the work.

One thing that either John or Lindsey came up with was to cut holes in the field of the template to lighten the weight when handling, it it would lower the shipping cost also, maybe.

One caveat about the holes is if the template is being used for a class make sure that people are aware that the lightening holes are not for cutting just for ease of handling. And yes we had a kite maker who learned that the hard way in front a World Kite Museum class full of other kite makers who apparently have long memories. Very Happy
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TBHinPhilly
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PostPosted: Tue Mar 08, 2011 5:59 pm    Post subject: Reply with quote

Will - that's very useful info.

And now that you have the template, does that mean there is a production version of the Chiroptera glider in the works?
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planish



Joined: 19 Aug 2008
Posts: 3696
Location: Canada, New Brunswick, Sackville

PostPosted: Wed Mar 09, 2011 1:39 am    Post subject: Reply with quote

Adhesive aluminum foil tape does a good job of protecting the edges of posterboard templates.

It usually comes in 2" wide rolls, but I slit it into four 1/2" wide strips. It's a bit tricky to apply to convex curves, but it can be done.
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Fore Check
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PostPosted: Wed Mar 09, 2011 10:13 am    Post subject: Reply with quote

Confused

Nice find, but... I just uploaded a DXF of the following to get an "instant quote"



The cheapest price I could get the quote machine to give me by going through the available materials was in a thin clear plastic at a cost of $103 for one piece. Shocked
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Will S
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Joined: 04 Jun 2007
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Location: Virginia

PostPosted: Wed Mar 09, 2011 1:51 pm    Post subject: Reply with quote

Did you have the file you uploaded only with the cut lines?
That's a good bit more than I paid for my larger and more complex templates Shocked
Pricing is high enough that I would only get templates made for things that I was planning on getting a dozen or more uses out of, but it's not too much on the grand scheme of things

Edit: I'm not sure what's up with that... I just made part similar to yours and got similar results. Options such as all the woods in the materials aren't there. I can still get that with my other file though. Not sure why.
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BigBlueSaw



Joined: 09 Mar 2011
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PostPosted: Wed Mar 09, 2011 4:02 pm    Post subject: Reply with quote

Try shrinking or splitting your template so that at least one dimension is below 24 inches. This will allow you to select laser cut materials.
Simon
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reynolds5520
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PostPosted: Wed Mar 09, 2011 4:37 pm    Post subject: Reply with quote

good tip Simon, thanks for taking the time to contribute here.
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robkite



Joined: 30 Apr 2004
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PostPosted: Wed Mar 09, 2011 5:04 pm    Post subject: Reply with quote

planish wrote:
Adhesive aluminum foil tape does a good job of protecting the edges of posterboard templates.

It usually comes in 2" wide rolls, but I slit it into four 1/2" wide strips. It's a bit tricky to apply to convex curves, but it can be done.


You could also soak the edge of the poster board template with CA Glue. Easier for those of us with little patience.

Credit for the glue method to kitesquid as he was the first I heard talk about it.
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