Mini Batman wall light - part 2

 From Part 1 we are cutting out the middle layer MDF panel that will support the LED strip lights.

The end convex curves are easy to cut on the 8" band saw. The
concave curve lines are harder to follow due to the width of the blade.

 

Checking and marking where we have to do some more trimming on the concave curves.

Now trim out those marked areas on the scroll saw.

Do another check and smooth out with a half round metal file - not a wood rasp.

With that done we need to transfer the front panel name to the middle layer panel so we know where to mark the rectangular cut out for the LED strip - to light the name.

Ready to mark the letter boundaries.

Using a Artline pen to get in there.

Here you can see the letter marks which guide the marking of the rectangular box. Drill corner holes so the blade can turn the corners.

For internal cuts the blade is removed and passed through a work piece hole, then mounted on the saw and blade tensioned.

Ready to go.

Nearly there.

Ready to go.

Tricky stuff... the LED strip runs from the outside over the top of the head and back inside to light the name. Enough for now...