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Hi, Has anyone used an inexpensive material such as MDF to make templets of the various pieces? Then once the templet is correct, use a flush trim router bit to produce the actual piece in the more expensive material?

Other benefits of having a reversible pattern might be:
1. MDF, having no grain or growth rings, is very easy to cut accurately and it sands easily to shape.
2. 1/4" MDF is cheap, light and easy to handle on a band saw & bench sander.
2. Eliminate the need to transfer the blueprint in reverse to produce a mirror image part.
3. If a piece where to be damaged during construction, an exact replacement could be produced easily

About ready to dive in. Thanks, Rick

yes works very well i used 1/4 inch luan ply for the templets and a 1/2 inch flush trim bit in my shaper just be very careful of the end grain and your fingers

I used 1/4 in hardboard for my templates and a hand held router with a flush trim bit to cut out my pieces. Found if you try to trim too much you will get lots of chipping. Cut out pieces with a jigsaw to about a 1/16 of the actual shape before trimming.

_________________
Want to build malahini "Mona Lisa"

My wife said "If I build a boat, she's getting a divorce."

Thanks for your replies. Off to the wood shop. Rick