Cookie cutters

[steve_g]

We can’t make cookies fast enough… Cookies are what we call cross cut log slices. Folks use cookies for any number of decorative purposes, brides buy them 30 and more at a time! Small “coaster” size ones sell for $1 to $3 each, candle holders $5 to $10 each and cake platter sized ones $25 to $50 each. We also make them into lazy Susans, signs and even table sized ones.
The smaller ones aren’t lucrative enough to spend much time on, so I was trying to figureout a way to improve throughput… My first idea was to make a holder to simplify re-facing the rough chainsaw cut using the bandsaw. My holder used embedded bandsaw blade pieces to grip the cookie and prevent the part from “spinning”and causing all kinds of havoc. This holder/jig made very nice looking parts upto 10” or 11” but still not fast enough. Also, the chainsaw cut with trim cuts gave us about 50% sawdust!
The version2 jig eliminates the chainsaw cuts… this “carriage” holds the entire log! Four foot and even longer tree/limb sections are accurately and reliably held, making quick work of an order with comparatively little waste. The carriage/jig is guided by the bandsaw miter gage slot and rolls on a couple of lawnmower wheels.
My jigs were modeled in SketchUp, imported into V-Carve Pro and cut from Baltic birch on the Bot…
Cookies over 10 or 11 inches in diameter still have to be surfaced on the Bot and their price reflects this! If demand continues, we may have to look into a larger capacity bandsaw…
SG

[rseeley13]

So then do you kiln dry them yourself?

[myxpykalix]

Do you have any problem with them cracking? or warping?

[rb99]

This saw design (lay down band saw) might be a good option:



I saw one at a steel shop that is programmable. It automatically feeds the material and continually cuts and feeds unattended.

[bleeth]

Crosscutting logs? You need a biiiig chopsaw. Seriously, much quicker than a bandsaw for smaller diameters like the coasters.
You can buy a huge circle saw blade like the sawmills use and set up a dedicated crosscutter with a log sled. Just make sure the motor is strong enough.
Depending on how far you wanted to go you could push/pull the sled with steppers or hydraulics.

First woodshop I worked in made cable spools and the area where logs were processed into the planks was the old fashioned one big motor, shaft, and leather belts to drive everything.
They had several 24" blades in a row that came down and crosscut all at once. Scary looking till you got used to it. Logs were mostly slash pine so the diameters weren't huge. Not exactly fine woodworking stuff.

[Ajcoholic]

http://www.woodweb.com/exchanges/mac...ts/485557.html

[steve_g]

We made a solar kiln for drying our slabs of wood… I’ll tell more about this later, but the cookies never see it! We get our logs from multiple sources, one is harvesting standing dead trees another is a tree service. The limbs we select aren’t fresh green cut… they’ve been sitting in the Texas heat awhile. Even then, we have to select limbs with tight bark… it’s not unheard of for us to glue or staple loose bark! Cracks and splits add character and desirability, the log the cookies in the last photo were cut from, had a lot of spalting and sponginess in the center, the bride is very pleased with them!
SG

[steve_g]

rb99…
Interesting! We recently bought a large Cyprus stump and are having a mill slab it for us. We’re looking at a ridiculously big cedar bole today… perhaps a chain or bandmill is in our future!
SG

[rb99]

Why does a bride want to give away spongy centered wood slices?

[Bob Eustace]

On refacing we just use a piece of ply with appropiate holes, drop in stuff to be sanded and run it thru the drum sander. Only used square stuff but it should work with cookies. If it lifts I would add a bit of vacuum to each cavity.