I have been gluing for four days now. Trying to make 2" thick wood into 4" thick wood.
Got it done now except the 11' long X 9.5" wide pieces. If I glue them, the piece will weigh 120 lbs.
I'll cut them to final size separately before gluing.
Look at this picture. Note how the cheeks are wrapped with flat bar. I will be using 3/8" X 4" wide flat bar.
Note the very end of the trail cheek where it touches the ground. This is the hardest part of the bend.
I have a friend that has a CNC wood carving machine. He cut out my wood template to exactly the size I wanted in 5 pieces.
He sent me a DXF format file of the end piece of the cheek. I sent it to another friend with a Plasmacam CNC. He was able to cut two of the end cheek pieces out of 1/4" plate and weld them together with a 4" spread. I intend to use this jig to bend the 3/8" X 4" flat bar around so it will match my cheek tail.
All the holes in the plate will allow C-Clamps to be used to hold everything in place as the bending progresses.
I think I will have a modern blacksmith shop help me with this.
I think this effort will help ensure a good metal to wood fit.
That is important to me.
The rest of the flat bars are straight pieces and can be cut and welded.
I am facing challenges that I never faced before but it is fun.
One thing at a time.