I picked up a package of 1/4" brass threaded inserts from Lee valley tools last week as well as a knurled set screw to hold the pencil in place.!http://www.leevalley.com/images/item/hardware/jigfixtureparts/44z0201s1.jpg!
I had a piece of mahogany lying about that had the height and width i needed so I cleaned it up with my fore plane and proceeded to mark the stick out to recieve the inserts and hole for the pencil
The centering of the inserts was easy using the drill press and a fence to line things up on the center mark from my smaller gage.
To make sure the hole were equidistant from the center I used stop on the fence and drilled the first hole them flipped the stick round and dropped in it's mate.
the layout took about 15 minutes because I wanted to check everyting but the actual drilliing was only about 5 minutes.
Here's another shot showing how I made the centering pins from some 2-1/2" bolts with the heads sawed off.
I was going to use brass rod for the pins but the Borg needs $18.50 for three feet of 1/4".
What they don't know will kill them.
I layed out the top curve with a french curve and ran it through the bandsaw.
It took about an hour and half of piddling and about 20 mins actual work to make this.
Question... Am i anal enough to put a finish on it?
p.s. The complete project is in shopnotes VOl 15 issue 86 page 24...