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Step
1: Getting Started
The
first step is to make your full-size patterns. There are two
ways you can accomplish this. The first is to follow the drawings
provided and make full-scale patterns for parts A through
H. Begin by drawing 1" grids on pieces of cardboard or artist's
board and then duplicate your drawings onto this larger grid.
The optional method involves going to a local copy center
and enlarging the patterns provided here by using a large
format, roll-fed copy machine. These machines typically enlarge
up to 400% in a single pass, so you'll have to make multiple
passes to get to the desired dimensions.
Once
you've drawn (or copied) your patterns, cut them out and trace
them onto a 6-foot and 8-foot length of 2" x 12" stock (we
used yellow pine). Work around any knots or defects in the
wood and for maximum strength, be sure to follow the grain
direction indicated by the arrows on the drawings.
Next,
cut your stock into manageable sized pieces before attempting
to cut out the final shapes with your bandsaw, saber saw or
scroll saw. The saddle (G) can
be made from your choice of 2" x 12" stock, then shaped....or
from 3/4" stock (H - not shown) and then upholstered (see
Step 11).
Cut
the braces (J) to size and chamfer
the edges using your Table Saw, Disc Sander or Jointer.
Step
2: Drill the holes
for the handle, eyes and tail where noted in the drawings.
Drill the alignment holes in parts B,C,D,E
& F, as shown. Locate these holes
very carefully since they will be used to align the various
parts of the horse during assembly. Drill the holes for the
legs (parts B & C)
from the back, being sure not to drill all the way through
the stock to their front sides.
Step
3: Sand all contoured parts
using your disc and drum
sanders. Tape the two rockers (A)
together with double-faced
tape and pad sand them together at the same time to be
certain their contours are identical. See Fig. 1.
Step
4: Use the Shaper
with a Tongue
Cutter to create the 1/4" deep groove in the back of the
head (E) that will accept the rug
yarn mane. See Fig. 2
Continue . . .
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