Cut and Attach Top and Bottom Panels

4:22

8:20

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Halloween pumpkin out of Pallet wood

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What happens here

Once the top and bottom panels are traced, use a miter saw to cut the top and bottom panels from the wider glued-up boards. Make sure to cut slightly outside the traced lines to allow for sanding. Take the assembled hexagonal structure with the top and bottom panels placed on it and bring it to a band saw. Carefully cut along the traced lines on both the top and bottom panels to match the hexagonal shape of the main body. A 3/4-inch blade on the band saw is recommended for straighter cuts. After cutting, bring the panels to a benchtop belt sander. Sand the edges of the top and bottom panels to remove saw marks and achieve a flush fit with the hexagonal body, leaving as little of the pencil mark as possible. Finally, apply wood glue to the perimeter of the top and bottom panels where they will meet the hexagonal body. Attach the panels, using a rubber mallet to gently tap them into place for a flush fit. Wipe away any excess glue with a damp rag.

Goal: Cut and securely attach the top and bottom hexagonal panels to the main structure.

Tools and materials

3/4-inch Band Saw Blade
Wood Glue Titebond II

What they say

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indestructible so just be gentle well that was drying I then took the panel though we did earlier slice didn't have to create a top and bottom piece of our pumpkin here and I set it on top then I traced the hexagon over to create a perfect match I also marked out with a 12 o'clock spots were to know that there's only one way it could fit once it was done we were ready to bring it to our band saw and cut this puppy out on my bandsaw I'm using a 3/4 range of blade specifically to make that cut as straight as possible once everything was cut out leaving as much pencil mark as I could I brought it over to my bench top belt sander to clean up as close to it as possible mostly because I want a nice tight fit when they get installed when he came down to installing the tops and the bottoms my strategy was simple leave the exposed weathered pallet wood facing to the top so when install on the bottom first I'm bound where the 12 o'clock points were sat at the shell right over it and hits it and installed flush took a damp rag wiped all the excess wood glue out use a little mallet to really seat it flush and be done with that part flip the back over and I did the same for the top really make sure you take your time to don't push it too much in because if you do well now you took a little bit of surface area away and it doesn't sit flush after we've got done

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