Vega Sky Center

Sitting atop the sacrificial circle of plywood is the little beast, the "Bosch Laminate Trimmer/ Router" equipped with a 1/4" up-cut spiral bit, that will be generating tons of flakes of polycarbonate as I cut out the disks that will form the knife-edge baffles. Attached to the laminate trimmer/ router base is a "Jasper Circle Guide" jig, to which the setup was slipped onto the pin that sits in a hole at the center of the sacrificial piece of wood. Upon close inspection of the Jasper Circle Guide jig, you will see a collection of predrilled 1/8" holes that are meant to provide 1/6" incremental diameter size adjustments from 7" to 18" for this particular jig. To determine the exact diameter of for the knife-edge baffles to make, I measured the outside diameter of the main tube (7") (I could have measured the inside diameter, but acquiring the outside diameter provided for more accurate end result) and subtract the wall thickness of .100" times two giving me .200", which gave me 6.8" then accounting for the thickness of the ProtoStar FlockBoard of .0625" multiplied times two came to .125", and subtracted that amount from the main tubes inside diameter of 6.8" gave me size I needed to cut the circles of Lexan to for the knife-edge baffles, which came to 6.675" inches in diameter. Next, divided the 6.675" by two and got a radius of 3.34". With this figure, I took the Jasper jig and router setup and moved them to the hole that gave me as close a radius of 3.34" as possible by measuring from the center of the 1/8" pin in the sacrificial circle of wood to the outer cutting edge of the up-cut 1/4" spiral router bit. This proved very successful in producing very accurate baffles that fit the interior of the main tube so well and snug, I did not have devise a means of holding the baffles in place. Of course, you will see the process in the upcoming collection of pages.

NOTE !!!!! --- I used piece of non-slip rug mat to keep my router setup from sliding around. It did a great job!

You can purchase larger jigs as needed, but they can carry a surprisingly high cost. Therefore, look for deals where you can; eBay and Amazon could help.

I know that I am getting very wordy with my description of the process to make the baffles for the "GJD", but I believe once you get into it, you will think its well worth the read.

!!!!! A T T E N T I O N !!!!! --- PLEASE READ AND UNDERSTAND ALL OF THE SAFETY INSTRUCTIONS FOR YOUR POWER TOOLS AND ALWAYS WEAR EYE PROTECTION AND A DUST MASK WHEN APPROPRIATE.