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I completed this project a few months back. The original pattern by Alex Fox was approximately 7" square and was designed as a single piece. Wanting more I decided to up the stakes. Wanting something to really show a presence for display I enlarged the pattern so each quarter of the pattern was 11" square. I stack cut each layer by 4 pieces with 1/8" baltic birch ply. Overall there are 8 layers to this project. The next step after gluing the 8 layers together was to sand the edges to create perfect 90 degree corners so no gaps showed where the 4 quarters of the project were glued together. The frame is made of 2" thick popular with walnut applied to the corners for a slight contrast. Overall this project measures over 24" square. Thanks for looking.

Been away from the saw for 2 1/2 months with a bad back and some other medical issues. Not exactly cured, but finally could finish up some intarsia projects where the parts were sitting around. Also cut out a wolf pattern just to see if I stilled had a little sawing MOJO. Nothing spectacular, but it felt good to get back into the swim of things.

I will take the credit for the cutting only of this Sue Mey pattern. My wife did all the painting!

G'day all, have just finished these 4 portraits of Marilyn and Audrey. Audrey Hepburn was the most beautiful woman ever (with the exception of the wife) IMHO 440mm x 360mm. 3mm marine ply from Bunnings, Couldn't tell you what the veneer is, probably some Indonesian rainforest timber. The frames are Radiata Pine 2 stained walnut and 2 stained dark mahogany. I cut these with a #1FD new spiral and a #2 FDUR I can't remember who did the patterns, I want to say that Audrey is by Grandpa but ????????

The shoulder is getting better. Did this today, Sue Mey design made out of 3/4 Walnut. Took a little longer than usual but it feels good to be back at it.

A cutting I did for my son's rec room. Cut out of baltic birch and finished with lacquer. I don't remember who made the pattern.

After three abdominal surgeries and ten weeks in the hospital over a seven month period, I’m finally back on the scroll saw! It was like riding a bike, a little wobbly, but quickly became as easy as it used to be. The biggest problem I had is my back is hurting. I lost about 30 pounds in the hospital stays and lost a lot of muscle mass, so my back is very week. I’ve gained most of my weight back, but working on strengthening my muscles. I’ll be in the shop all day tomorrow as I have a lot of catching up to do!

Ok here’s my cut for the challenge! Can’t remember if this is Sue Mey or Shelia Landry’s pattern.

McHale's Navy was a popular TV comedy show that appeared on the scene on October 11, 1962. Wow! was it really that many year ago. Tim Conway who played the part of Mister Parker passed away recently so I thought it might be time to come up with a tribute sign for the show. I cut mine completely out of curly maple and improvised a flat wave base to stand it on. If you have any suggestions of other TV shows that might make good sign topics, please drop me a line and let me know. Free Pattern:

I've been meaning to post this for a couple weeks but I've had a lot going on and keep forgetting.. I was moving some boxes around and doing some cleaning in my loft a few weeks ago.. seen my box that the EX came in.. I noticed the label said China on it.. had to go downstairs and look at the tag on the saw Sure enough.. All this time I thought my saw was the one made in Twain since I bought it before they really released the China made saws in the USA.. But.. the guy I got it from did mention that they was going to be bringing the Excalibur back and he seemed to know what he was talking about.. He claimed to have won the saw in a drawing from his work Christmas party or ? and he had no use for it.. How they got their hands on the China made saw before they released them in the USA is beyond me.. I'm just wondering if this is why my original blade chuck was basically junk... why my back knob turned so quickly out of adjustment and the thing sounds about like it's falling apart when running it very fast.. it is smooth but seems noisy to me.. but was always that way.. not being around a EX before I didn't know if they was just a norm for them or not.. But I've always kinda shook my head in amazement that people love these saws so much.. Now I think I just got a lemon of a machine.. I really see how someone could like them as my saw does cut nice.. but it just seems cheap made and have had issue after issue with it.. Maybe the first batch trial run machines that came off the new factory line.. So that kinda explains a lot to me.. I've been very temped to take the whole thing apart and give it a good going over.. almost sounds like a greaseless DeWalt running... so now I'm wondering about the bearings etc.. it is noisy though smooth.. sometimes it makes a loud clanking sound at the back of the saw like one of the links or the connecting rod or something is hitting the side of the machine... probably is, LOL Sure cuts nice.. and I think if it was as quiet and smooth as my other saws have been it'd probably be my favorite saw.. It just cannot be right.. not the way people rave them so much..

Now if I can just do it.

I was looking through the pattern gallery and found this, I did modify it and at the last moment, I free handed the border.

Simple project that should have been fairly quick took me most of the day. After cutting sanding and finishing the wood part I dropped it and it broke pretty much in half. I was able to prune a couple of limbs and glue it back together. Tried four different backers. Wound up with a slate backer and base. Glad I'm not trying to make a living at this!

My 6yr old daughter "helped" cut. My hands were on top of hers, but she painted the back ground. Wanted us to make mommy something together for Mother's Day.

That's how mine are on the EX.. and that is also how they were with the original ones.. being loose like that keeps it from binding and breaking something..

I don’t know about the Seyco or EX type saws, but the clamps on DeWALT saws are loose like that. Once tensioned, they don’t move.

Glad to hear after all of those struggles Dan t hat you are on the mend and back at the saw. Sorry it took so long for you. Listen to your body and take it easy and take breaks at the saw as everyone says. Happy cutting.

So glad that you've finally come out of that long, long tunnel but Please look after yourself Dan. It's great that you are back at your saw, but take time out often to rest. Your back may need strengthening but gently, gently does it. It's the only one you have. With Best Wishes, Brenda x

Glad all whent well. Glad you will soon be back to you old self or better one of you. We all want is you back. Barbara

While it is great to hear that you are feeling better and back to scrolling you need to take it easy and have a break every 20mins or so until you are completely back to your old self. Maybe a 2min. walk around the garden and then back to it, that's what I have to do when my back starts to hurt. Please take it easy Dan. Forgot to ask are you back at work yet? Marg

Good to hear you are recuperating and getting back to the saw!

Slow, but it is healing. Thanks for asking.

Dan, Glad to see you back to scrolling, take it easy Paul, How is your hand healing, getting better? RJ

DO NOT OVER DO!! So glad you are feeling better. I really haven't been able to do any real physical stuff since last Oct. Lost 20 and I am a little guy. I know what you mean about being weak. Funny how quickly the muscles deteriorate. Now I have a 5 lb. lifting restriction on my left hand for a while, and I can tell that arm is already weaker... But I can still scroll.

Sounds like you are ready to get back to work. Just remember to have rest breaks, when the body says I hurt it is a good idea to listen and rest. I am happy that you are able to get back at the saw. Look forward to the new projects.

I am known for keeping things my grand children do not have room for. In your case, if there were room, I would place a couple of blocks under the rockers and a protective pan on the seat and use it for a plant stand. Maybe (just maybe) it will give the parents in question an idea for the near future. OH yah, I did the same thing with the rocking chairs, which found the rightful homes when seen by the right kids and grandkids.

On the night before my wedding, Dad, the best man and myself partook of few brews and Dad's one piece of advice was : "Make sure you remember, YES DEAR' and you'll do alright" Must of been something to it, because 42 years later, I';m still saying it

It turns out that flowers have seldom been the subject of my scroll saw work. I only remember three such projects. The project that I favour is one called morning glory: I liked it so much that I made two of them. The pattern is by Mike Williams.

I added the pattern for this to the library if anyone's interested.

"Peace" sign project. 4 layers, MDF 1/8 inch Flying dutchman ultra reverse blades #1 Peace pattern

Like everybody else has said, once tightened and ready to saw, does the slop go away? My EX is loose but not quite that loose. Once the lever is thrown, it's tight and all good. I love my saw with the Pegas clamps.

Sad, but it is my belief that it is not because it was made in China as much as it is the company having it made is willing to accept low standards. They write the spec and do the end quality control. I they accept poor they will get poor. If that is the way all new Ex's are, it will be the final demise of the Excalibur. Sad.

very nice job

Thanks y'all, Appreciate the info

That one and the dogs playing poker sure bring back memories, thanks for that

My only experience with other saws is the porter cable, it was a good saw, but just good enough to convince me to stick with the hobby. Then I found my ex on craigslist. I wish I was near enough to somewhere that had other saws I could try, I would like to see the difference between them. But then again I hear people saying you have to get used to the different brand, so a five minute try out is really not going to matter much I think. I never did bevel cutting on the porter cable so tilting the table to do that is something I never tried, but I do love that the ex style saws tilt the head. That alone is enough to make me think twice about any other saw. I have no noise in mine at any speed, I generally keep the speed knob around 3/4 though. Go ahead take it apart, it will be interesting to hear what you find. You might as well, you know if you do not, it will be something that rattles around in your mind bugging you to no end.

Beautiful patterns of beautiful ladies. Excellent work John. Love the frames too. Marg

Love it. Marg

Great news Dan. Just don't over do it. Slow and steady wins the race.

Beautiful job on both John. Jeff

Nice work, two beautiful women....

Sorry don't know why my post is so big. I must have done something wrong and don't know how to fix it.

Wish I could find a pattern for them playing poker.

Steve good used some modeling clay "filmo" or "sculpy" to do the same thing. I've never tried it though.

I don't have experience with clay but I have used stuff called inlace.. It comes in a can and you mix it with a activator.. Comes in several colors.. Problem I have is.. I never have the color I need, LOL Not sure if you've ever mixed up or messed with fiberglass or bondo ( body filler in the automotive industry ).. This inlace smells and acts just about like a fiberglass resin.. not as hard as the stuff I've used in the autobody world but it's very similar.. I only have Red and Black colors.. Bought it several years ago for a few certain projects and haven't used it since.. I keep thinking I need to use it up if it's any good still.. Below is a picture of a key rack I made for my son about 2010.. I cut the design out on 1/8" Oak and then filled it with the red inlace then glued to a 1/2 or 3/4 Oak backer.. Guess it turned out okay and still looks good.. I also used to make the oval kaychains Steve Good patterns. and cut them from 1/16 then glue to a backer and fill the cutout with this.. Made those in 2008..and mine that I carry everyday still looking good. When filling it I would fill it higher than the wood.. then sand it flush on my belt sander.. http://www.inlaceonline.com/text/products/kits.html

The actual pattern is nice, I just wanted simplicity and something to put on my shelf above my saw.

If Spring is in the air then that means love is too.. A Sue Mey design.

I originally planned to wait and see if these really work but, this challenge came up so, maybe other members want to try it also. You can buy these professionally made but, I just used scrap pine. Height about 5 3/4", Width about 4". 1/4" dowels abt 1 1/2" and mesh material to put cotton, dog hair, twine or other materials a Hummingbird can use to start a nest. I used the easy way out and just cut one side of the roof 3/4" longer than the other side to over-lap but, it could be miter cut.

I think I have posted these here before, but they are some of the most recent ones I have cut.

In keeping with Alien's theme, I did this, then the wife liked it and took it, so naturally I made it for her