Router Jig

While waiting for the skis to finish laminating, I set about making the router jig. This is what allows you to thin out the skis at either end while keeping them fatter underfoot. This results in a strong mounting area for bindings (this means less chance of bindings ripping out) and it also gives the skis a bit more pop.
The jig is made up of 2 parts:
The Rails...

And the Cradle ...

I know that I want the skis to be about 15mm underfoot and about 3mm tip and tail. If I'm honest, the next bit was mostly guess work!
I drew out a line 15mm from the top of a plank of wood, then a line 3mm above that. I marked on the midpoint of the ski and since the ski is symmetrical, everything I did on the front, I did on the back.
From the midpoint i marked a point 30cm away, then another 30cm from that. between these 2 points I drew a diagonal line connecting the top of the piece of wood to the 3mm line.
Basically then all you need to do is have a steady hand and a band saw.
I cut the shape out then cut the plank in half to get 2 identical rails.
I then used off cuts from the core to make the separates you can see in the photo. Nail it all together and boom... Rails.

Next for the cradle. This will run on the rails and keep your router level so the skis are the same thickness across the width. The dimensions really vary on your router but basically it should look like this.

The router should fit snugly between the guide strips and there are 2 strips underneath that means the cradle can fit over the rails without too much movement side to side but enough to slide along the length of the rails.
I routed a hole in the base plate big enough to fit the routing bit through.


All that's left to do now is wait for the core to laminate then I can get onto routing tomorrow!
Oh yeah, and tidy up...