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Old 02-05-2006, 10:29 AM   #6
Diggin Jiggin
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Join Date: Nov 2004
Location: plymouth,ma
Posts: 1,142
ok, to rough these out quick here's what I was doing.

I took a 2' lenghth of ayc and cut it down the middle on the bandsaw so I had to 3/4 thick pieces. then I hit the cut surfaces real quick on the belt sander to take the marks out from the saw blade.

Then you basically make a stencil of the shape you want and see how many you can fit on one board. You want the belly of the plug on the outside of the board. Alternate them from one side to the other and I was able to fit 2 on one side , 3 on the other. Depends on how big you want them.

Now you take the board over to the router table and with a 3/8 round over bit, round over both the sides.

It should now look like this...
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