Step 2: Using the template with a flush trim router bit

To use the template to make an exact copy of the curved seat, you'll need a flush trim router bit.  Because these pieces are narrow, it is easiest to use a router table, however, it can also be accomplished with a hand-held router.  Take your template and draw the outline on a piece of wood.  In this case, I'm using 3/4" birch plywood.  Cut the shape out with a bandsaw or jigsaw about 1/16-1/8" outside the line.  The end result is a rough cut piece slightly bigger than the template which will be trimmed smooth using a router.  Double sided carpet tape is sufficient to hold the two pieces of wood together for trimming.

A flush trim router bit has a guide bearing which is exactly even with the cutline of the knives (pic 2).  The height of the bit is set so that the bearing follows the edge of the template as the blades trim the other piece of wood.  The end result is an exact copy of your template.  When the trimming is complete, the 2 pieces of wood are simply pried apart and the carpet tape removed (pic 3).
<p>Success! For my seat I used 2 pieces of birch plywood and 2 pieces of mahogany luan plywood, and ran them through the planer until they were nice and flexible, which ended up being about 1/8&quot; thick and 2 layers per piece, making the final seat 1/2&quot; thick and 8 plys. I layered the birch on the faces and the two mahogany pieces in the center, and glued it up with Dap 00203 Weldwood Plastic Resin Glue, which I have read is the best adhesive to use for laminated bent wood projects.<br><br>I used your PDF template to cut the form out of 3/4&quot; MDF sheets on my CNC router. The whole form is glued and nailed together with a pneumatic nail gun. I found that the bars that span across the form (see the 3rd photo) are essential to keep the form rigid and provide clamping pressure in the center where the clamps can't reach.<br><br>The final seat is rock solid and has the weight and feel of a skateboard deck. Thanks for your instructable!</p>
<p>Fantastic job! Super nice form. Glad it was helpful and thanks for sharing yours!</p>
In fact you don't need the steamer nor the seat press at all. I've build very similar seat (based on the same rib jig) using 4 sheets of 2mm plywood glued together with wood glue and put on the same craddle (before the glue dries) and held together only with clamps. Visit forum.atomiczombie.com/showthread.php/6620-Warrior-by-Ducati-D
This is a great instructable, thanks for sharing. The seat looks great. <br> <br>I made a steel version of the warrior and would like to make a few of these seats for future builds. The link you provided for the seat template seems to be dead? Would you perhaps have the file? <br> <br>Thanks.
Thanks! Try this link. I was able to get it to work. I will also try and add a PDF to the instructable just in case. <br> <br>http://ia700209.us.archive.org/9/items/RibSeat/Rib.PDF
What do you know? I was able to add the PDF and it was very easy. Hope this helps. Have a blast on your Warrior!

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