For those really big jobs!
SHOP OWNER: Aurele Delaurier
LOCATION: Winnipeg, Manitoba, Canada
Whenever I plan to build a new project, I look for a few things. The idea must be unique; I like it when the item I'm copying is one not typically made of wood, and I enjoy making things that are not to its actual scale. Since this project met all the criteria, I decided to build it.
I glued together two pieces of 3/4" x 12" x 48" MDF (Medium Density Fiberboard) and cut out the shape of the wrench.
I cut six pieces of 1/4" birch plywood for the raised sections, and glued them to the wrench.
Using a flush trimming bit in my router, I followed the profile to remove the excess plywood from the wrench.
To make the nut, I glued together three pieces of 3/4" x 8" x 8" MDF and drilled the inner hole. I cut the outer circle to the maximum diameter of the nut (measured from point to point on the hexagon).
To bevel the inner and outer edges of the nut, I used a 45-degree chamfering bit in my router. I beveled the outer edges to the exact width of the nut (measured from flat to flat on the hexagon).
I set the miter saw to 30 degrees and cut the nut to the upper beveled edge.
This shot of the wrench on our couch gives an idea of its size. The wrench measures 47 ½ " long and is 2" thick. The nut is 6" wide (flat to flat) and is 2 ¼ " thick. To give the wrench and nut an authentic look and feel, I used hammered-finish paint. Because this wrench is made of wood, I decided to route the words FORGED STEEL in as a play on words.. . . Aurele Delaurier
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