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AmericanWoodworker oc.roaeazooz 59
TIP-
OVERLAY \
Fre.A B o w L n v r r u A T t o N S BO.TUFF G
Bow Klrs
I usedkitsfrom Bingham
Projects (see"Buyer'sGuide,"
p.64).You canselectfroma
widevarietyof woodspecies
andBo-Tuffcolorsfor yourDow.
Thekitsinclude:
e Bo-Tuff- fiberglass stripsthat
givethe bow strength.
- r Fourwood strips - two have
ntseny' a slighttaper.Thefat end
OVERLAY
goesto the middle.
r Tip ovedays- micartaplastic
usedto reinforce the bowtios.
e Riserblod<and ovedays-
blocksof woodthatformthe
handleand arrowrest.
. Peperpattems- for bow and
formshapes.
r Steelhardwarcfor the forms.
o Prssurehosewith fittings.
. Metal plssutstrip - distrib-
uteshosepressure evenly.
r Indexpin - keepsthe riser
blockanchored in the form.
o PlasticLaminate. provides
a smooth,non-stick surface.
o ReverseTaper Strips - oppo-
siteof the bow striptaper.
PLASTIC . Themostat - limitsthe tem-
LAMINATE
perature in the heatbox.
r Slow-setepory. allowsfor
unfrenzied assembly.
. High temperaturemasking
tape - protectsthe Bo-Tuff.
rconstruction video
\ LocKlNG
1t4"/ W2' HARDWARE
PLYWOOD L/
4 PIECESOF 1/2"
SPACER i\ a-z
CDX PLYWOOD
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Fre. THERMOSTAT
Frc. D WtntrucDtRcnRvt
AmericanWoodworker ocToBERzooz 61
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fiAutt the bottom pair of laminationsagainstthe index pin on the form. Set the riser block over these laminationsso the
\-thole drilled in the backfits over the index pin.The top laminationswill lay over the riser.Plasticwrap protectsthe form
from epoxy squeezeout. Wrap filament tape around the laminationsto keep them from sliding around on the bottom form.
.t
-l -l -l
fl Use a bridge shapedtemplateto mark the ntign a paper patternwith the limb's centerlineand the string
I \,f length of each limb (top of the bridge)and I I groove mark. Cut the shape on a bandsawand finish shaping
to positionthe groovesfor the string (underside the edgeswith a drum sander.
of the bridge).
-l
es and a dust mask. Q rite the string
I ! grooves with a
23. Draw a centerline along the length of the rat-tailfile.The angle
bow. Mark the limb cut-off point and the string should be approximate-
groove location (Photo 10). Cut the limbs to length ly 70-degreesto the
tabletop.Checkthe
on the bandsaw. Fiberglass is hard on blades, so use
backsideof the bow
an old one. If you plan to make a lot of bows, con- often to make sure each
sider buying a carbide blade. side is symmetrical.
24. Mark the limb tip shape (Photo 11).
25. Rough<ut the shape of the bow limbs on the
bandsaw. Use a drum sander to finish the shape.
26. Start the string groove cut with a triangular
file. Follow up with aratl^1lfile (Photo 12) and a -l
fine chain-saw sharpening file. Be sure each string Q Oue to variations
I r-fin shapingand
groove is cut at the same angle and depth. The
sanding,one limb may
exact angle is a bit arbirary but should be around be stifferthan another.
T0degrees to the tabletop. To test, string the bow
27. Reinforce the tips with a tip overlay (Fig. A). and measurefrom the
end of each riser overlay
Cut and shape the part of the tip overlay that lays
to the string.A stiffer
directly on the bow surface. Let the outside edges limb will measureshort-
overhang the bow limb for now.
28. Remove the tape at the tip and lightly sand
the area with 120-grit sandpaper. Use regular
epoxy to glue the tip overlays to the limbs. Lightly
clamp in place and let the epoxy cure overnight.
'l
File the tip overlay flush with the bow edges and 7l CnecUfor twist in
-Ittre
string grooves. I limbs. Make
29. Remove the tape on the bottom center por- a tiller stickto pull the
string and flex the
tion of the bow. Scuff sand the area and epoxy the l i m b s .l f o n e l i m b i s
riser overlays to the bow, leaving a l/2-in. gap twisted, mark the side
between them. that is high. Sandthe
30. Check the bow for uniform limb stiffness high edge to remove
enough materialto cor-
(Photo 13) . It's best if both limbs are the same stiF
rect the twist.
ness.
31. To limber up a stiff limb, remove the string
and lightly sand the fiberglass surface on each side
of with 120-grit sandpaper. tf you still end up with
1Y^ one lirnb slightly stiffer rhan the other, that's OK-.just
I k\uraw tne
I r-.f arrow notch make sure the stiffer limb is at the bottom of the bow.
andthe hand-grip 32. The ltext step in tunine your bow is called
p r o f i l e su s i n gt h e
"tillering". Cut an 18-in. tiller stick and use ir ro
two patternsprovid-
ed in the kit. cut the stretch the string and mirnic bow pull (Photo 14).
profile for the top Sight down the surface of each limb and look for
first as shown and nvist. Mark the side of the limb wherever it risesfiom
then laythe bow on
tl-rehorizontal. Then, sand that edge to correct twist.
its side to further cut
t h e h a n d - g r i pa r e a . 33. Use paper patterns to trace tl're bow srip and
arrow notch oltto the riser block. Revcrse the arrow
notch template for a left-hand borv.
34. Rough out the grip shape on a bandsawwith a
3/8-in., 4-TPI skip-toothed blacle (Photo 15). Clamp
your bow in a vise and rasp the riser-to fit your- hzrncl
(Pl.rotol6). I useclrnany shaping rools, f)orn por-table
drum sandersto files, r-aspsand sanding blocks.
35. Finish sand all the bow surfaces.Start rvith I 2(l
grit and rvork your way up to 400-grit t() rclllo\.('
scr-atch patterns fl-onr the fiberelass.
I fiuse a combi- Spray the bow with sevcral coaLsol gloss
I \-fnation of
r a s p sa n d s m a l l varnish, let clry - then give your borv a tra.
d r u m s a n d e r st o
custom-fitthe bow f
t o y o u r h a n d .O n c e t
you get it right, start B u Y E R ' sG u r o r
s a n d i n gt h e w o o d Bingham Projects,(801)-399-3470,
areaswith 80-grit
www. bi ng ham projects.com
s a n d p a p e rD. o n ' t
. 302 - RecurveLaminatingPressKit with Video-
s a n dt h e f i b e r g l a s s
surfaceswith any- choosebow lengthand limbwidth (includes3-01
t h i n g l e s st h a n 1 2 0 - Instructional materials, f ull-sizeblueprints& video)
g r i t s a n d p a p eo o 2TC-ThermostatControlfor laminating oven
rr
y o u ' l l l e a v ed e e p . 6300- RecurveLimb Lamination Kit - choosebow
scratchesthat are length,limbwidth (1 314"or 2"),drawweight,draw
hard to remove. lengthand glasscolor
r 403LVC- RecurveRiser- choosecolor
o 406'1- Epoxyglue- 314pt
. 4028f - Bow tip overlavs- choosecolor
c 1707- Bow string- 2 recommended
o 415- 314"Filamenttaoe
o 415 - HighTemperature maskingtape - 2"
(l ' I ]rinisr' yort
. 58" or 60" RecurveLimb Lamination Kit - includes
F-q*
I / uow by sus- Bo-TuffE glassand wood strip laminations.
p e n d i n gi t f r o m a
*ii# wire attachedto the
Total Bow SuppliesApprox. $250
(Additional BowsApprox.$120)
lti;r"1..t;;"'.,,.* string grooves.Spray
severalcoats of gloss Home Genters
. 4 sheets 112" CDXplywood
varnishto protectthe
.1-2x2x8'pine
b o w a n d b r i n go u t
o 5 - 4-in.x 1-112"octagonsteeljunctionboxes
the wood's beauty.
.8 - 112"EMT set screw connectorsand lock-nuts
. l0' of 112"EMT conduit
. 1 - 112"metallicchordconnectorwith strainreliefgrip
. ' 1 0 ' o fb l a c ka n d ' 1 0 ' o fw h i t e ,1 6 g a .s t r a n d e d
high
temp. insulatedwire (1bo'C)
o B - Wire nuts sizedfor 3 -169a.conductors
. 1 - box coverwith centerknock-out
. 114"#10-32greengroundscrew
. 4 - porcelainkeylesslampholders
. 1- Portableheatercord set, 3 conductor,'16gauge
groundingtype HPDor HPN ('105"C or more)
i!
Total MaterialsApprox. $150