Table of contents
Materials
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Tools
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Making the Project
By Don Worley
Start with 2″ by 2″ (51mm by 51mm) stock and use a band saw to cut it diagonally (See Cutting Triangular Blanks). Note: It is dangerous to use a table saw for this cut. Copy the pattern, cut it out, and flip it over. Trace the flipped pattern onto the flat back of the blank, and then mark the material outside the tracing to be removed. Use a band saw, coping saw, scroll saw, or a carving knife to cut on the line, resulting in a triangular blank
Cutting Triangular Blanks
Set a table saw blade to 45° and cut halfway through a scrap block of wood, such as a 2 by 4. Cut from both directions to create a 45°-angled groove in the middle. Slice halfway down the length of the board through the center of the groove with a band saw.
Clamp the angled jig to the band saw table. Position a square carving blank in the groove and feed the blank through the band saw blade to create two triangular carving blanks.
Finishing the carving
Use a flap sander and 320-grit sandpaper to lightly sand the carving. Then, dunk the carving in water and blot it with a paper towel. Paint the face with medium flesh. Tint the nose and cheeks, and paint the hat, with tomato spice. Paint the mustache, beard, and hat trim white. Finish the carving with a coat of clear spray finish if desired.
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