Handmade Wooden Aviator Sunglasses (no-laser Cutter)

For my brother's birthday i decided to make him of wooden aviators. Since I didn't have a laser cutter I had to do them by hand, so my pair may be a bit rough.

Step 1: Materials

Sorry I didn't make pictures for this part but you'll be able to see what I used in later slides in more details.

Tools:

band saw
drill press
scroll saw
sander
sand paper
dremel ( optional)

Materials:

wood (duh) of your choice
old pair of sunglasses
gorilla glue (or other multi-material glue)
polyurethane

*There may be a few materials/ tools I have forgotten*

Step 2: Dismemberment

This first step is a bit of a sad one. Take apart the old pair of sunglasses making sure not to scratch the lenses and to keep the hinges attached to the sides. I my case I got an old pair of RayBans from Goodwill for about 2 bucks. I was able to easily detach the frames using wire cutters but it could vary from pair to pair.

Step 3: Main Frame

Trace the sunglasses onto the wood (in this case it's rosewood, which is one of my favorites) then cut it out on the band saw. Then, on the side of the wood, sketch out the best curve to match your face then cut it out on the band saw as well.

Step 4: Lens Slots

Trace the lens outline onto the wood face. Then draw a second outline just within that one barely smaller than the lenses. Drill a whole in the corner of the outline then put the scroll saw blade through it and cut it out. Next use the dremel to sand the corners down.

Step 5: Lens Chanels

Sorry I did not get a picture of this step. Using a dremel with a router bit, from the back of the glasses make a grove about halfway through the glasses that fits the lenses so they can sink into the glasses frames.

Step 6: Sides

On each side of the glasses drill a hole that fits the hinges. Then glue the hinges in place once at the right angle. Then keep them in place with the alligator clips until the glue dries.

Step 7: Finishing

I finished it with high grit sand paper then polyurethane. Once it finished drying I glued the lenses in place. Well that's pretty much, hope you enjoyed it. Let me know what you think in the comments. Thank you and God bless!