This afternoon I decided to 'machine' out the middle of the formers as per the plans. I clamped an old piece of 1/2 ply to the Miller and used it as a free hand router. I was quite surprised at how easily it cut. The direction of the cutter tried to pull it off to one side but I could easily counter it. Hey presto all cut out and ready to sand up.

Once I had cut around the lines I cut the piece out with a sharp Stanley knife on the centre line and a steel ruler to guide me. I then layed the cut piece on the other half, drew around it with 3mm allowance for the cutter and then cut the other half out.
My milling machine will run at 2800 rpm so using a new 3mm slot drill it was a nice Cut I have yet to remove the paper which I hope has not been on too long 😩 And had chance to stick too much. I am off to Ireland for three days and will be taking all the parts with me, on an evening I can try and get all the paper off.
The instructions call for bits of 1/4" balsa to be stuck to the building board and the centre frame glued to that. This only allows you to fix the bottom sheets and then you have to lift the frame assembly off the board to do the sides. Having thought about this I prefer to leave it on the base board and fit the sides as well. So I have left tabs on the middle frame which lift the frame up away from the board.

The blocks are screwed and lightly glued to the board. With it being varnished the glue may not take too well and I will be able to get them off at a later date🤔
So now I cut out the centre of the frame with a Stanley knife and modelling knife. Boy does my arm and hands ache after that. It took me nearly two hour of carefully cutting against the ruler, trying not to slip and loose a finger and keep,the blade cutting. 🤗 Well it's out now and I can fix it to the blocks. I cut the outside with my bandsaw and then sanded it up I think the tabs will cut off easily when I am ready.

Ttfn Brian
Edited By Brian Dickinson 1 on 20/08/2017 18:07:08