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| My Collar Rib Jig | Plexi-glass Shroud | Without the alignment ring |
The list of the supplies I used:
These are all the tools that I used:
Before I begin let me say that although this part might seem diffucult, it really is not, if you just take it one step at a time and don't be in a hurry. The procedure for making the Collar section was really quite easy and fun. First I started by printing the Collar layout pattern and the Collar rib pattern from the club site. I then carefully put together the Collar layout pattern, being sure that all alignment marks were aligned. Next, spray glueing the Rib diagram to some 1/4 inch plywood, I made four molding jigs (See 1st picture).Then using the Band saw I cut the 1/4 inch rod into 108 9 5/8 inch pieces.(this length varies by builder). Then came the fun part, After a few test pieces I found the correct settings for my wife's oven, (Don't tell her, she doesn't know I used her oven), was 300 degrees for 4 1/2 minutes. Working with 4 ribs at a time took me about 2 hours to form all the ribs, and let me say that I really had some fun doing this.
After I finished all the ribs I took them to another room, where my Collar Rib placement diagram was at. There, I created what I thought was the only way I could get the ribs in a perfect circle (see pic 4 below), I cut a close to perfect 19 1/4 inch circle and centered it over my placement jig, nailed it down. I then took one of those square peices of Plexi-glass and using my bandsaw I cut out a circle 14 1/2 inches and then cut an 8 inch circle out of the center with my Jig saw. After positioning the Plexi-Glass circle in the center of the rib placement jig, I used blue painters tape to attach the center of my circle to the placement jig so I could lift it up a little to place my ribs under it.
Since I could only afford one of those peices of Plexi-glass, I used it for the bottom and began to apply plummers goop to about the last inch of my ribs. I only attached about half of my ribs so I could still slip in another peice of Plexi-glass for the top at a later date. While waiting I also built 4 I-shaped supports and gooped them into place across from each other.
At this point I started work on the inside collar shroud which was 31 1/2 inches round and 3 inches high. The only material I had was some left over plexi-glass so I figured that this might look alright. After figuring out how long to cut it I ended up with 2 pieces 3 inches by 15 3/4 inches. This was exactly half of the circle I needed to make for the interior shroud. Next I made a form and heated the wifes oven to 350 degrees and cooked it for about 6 minutes. After forming the half circle I spray painted the inside of the semi-circle with flat black, two coats and then using plummers goop I attached it to the inside of the collar and decided that it looks pretty good, I mean with the way the ribs reflect off of the shroud.
The last picture on the bottom of this page shows what it will look like when it is done.
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| Shroud mold | With the plexi-glass shroud | Collar and Shroud assembly |
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| Collar Rib Layout with Alignment Ring | Without alignment ring | Finished Collar |
If you have any questions or comments contact me by