Rogue and MG-1 end panel replacements
Posted: Thu Jul 14, 2011 2:54 pm
OK - I fine tuned jigs, templates and the procedure and am pretty satisfied with the results.

The wood pictured here, starting from the top: 1. Vertical grain Black Walnut from dunnage salvage 2. Black Locust natural finish (harvested from the Steven's estate last summer 3. Black Walnut with sapwood edge from tree removal project last year 4. Black Walnut heartwood (flat grain) from same tree 5. Black Locust with dark walnut stain
Even with the jigs complete, these are quite time consuming to make as I'm particular about the details. Customer response to marketing inquiries indicate $85 per set including packaging and mailing to US address is a reasonable price. If I can tool up to make them a dozen at a time I could do OK at a lesser cost, but I don't see that happening any time soon. What do you guys think?
Other wood species on hand are Cherry, Oak, and Holly. My price for the wood on hand is insignificant, but If I have to go to Woodcrafter's for a special order, that would add significantly to the cost. Each jpb requires (2 ea) 6" X 13" X 1" rough or 3/4" finish plus (1 ea) 1.5" X 1.5 X 12" for the filler blocks. I'll make these out of any wood a customer wants to provide.

Router jigs for these end panels were somewhat problematic to design and construct. Each panel requires two routing operations; one for the front of the bottom plate and a second for the front panel edges. Additionally, left and right panels require mirror image operations resulting in four separate jigs. Assemblies pictured here are for left and right panels. Each assembly has a jig on the top and bottom to complete the two separate operations.

Shipped with each pair of end panels is a set of screws for mounting the bottom panel, and a set of wedges for the glue up procedure. It will be necessary to drill 1/16" pilot holes for each bottom panel screw as I can not be certain to locate them exactly without the final assembly process complete.
See more info here: http://www.facebook.com/media/set/?set= ... 9089484922

The wood pictured here, starting from the top: 1. Vertical grain Black Walnut from dunnage salvage 2. Black Locust natural finish (harvested from the Steven's estate last summer 3. Black Walnut with sapwood edge from tree removal project last year 4. Black Walnut heartwood (flat grain) from same tree 5. Black Locust with dark walnut stain
Even with the jigs complete, these are quite time consuming to make as I'm particular about the details. Customer response to marketing inquiries indicate $85 per set including packaging and mailing to US address is a reasonable price. If I can tool up to make them a dozen at a time I could do OK at a lesser cost, but I don't see that happening any time soon. What do you guys think?
Other wood species on hand are Cherry, Oak, and Holly. My price for the wood on hand is insignificant, but If I have to go to Woodcrafter's for a special order, that would add significantly to the cost. Each jpb requires (2 ea) 6" X 13" X 1" rough or 3/4" finish plus (1 ea) 1.5" X 1.5 X 12" for the filler blocks. I'll make these out of any wood a customer wants to provide.

Router jigs for these end panels were somewhat problematic to design and construct. Each panel requires two routing operations; one for the front of the bottom plate and a second for the front panel edges. Additionally, left and right panels require mirror image operations resulting in four separate jigs. Assemblies pictured here are for left and right panels. Each assembly has a jig on the top and bottom to complete the two separate operations.

Shipped with each pair of end panels is a set of screws for mounting the bottom panel, and a set of wedges for the glue up procedure. It will be necessary to drill 1/16" pilot holes for each bottom panel screw as I can not be certain to locate them exactly without the final assembly process complete.
See more info here: http://www.facebook.com/media/set/?set= ... 9089484922