Let's see how to make a wooden hand mirror. A task that at first I thought would be simple, but in the end it took a lot of steps to be completed. Here we are going to see how to make the wooden frame of the mirror, and in a next post I will try to polish a metal sheet to serve as a mirror.
I'm going to start by drawing the inner shape of the hollow of the hand mirror and the handle. To draw the interior gap the best I found was a tape from a belt sander. I put it on the 1cm thick oak wood and draw the shape. And with a tablet I draw more or less the shape of the handle.
Now I have to make a hole with the drill. And now I can insert the cutting blade of the Jig Saw, to cut the inner hollow of this wooden frame for the hand mirror.
Cutting with the jigsaw just on the line is complicated, so it is better to cut a few millimeters from the line and finish adjusting the exact shape of the hole with the sanding drum of the drill press.
Now I draw the outer shape of this wooden mirror and cut it with the jigsaw. Again keeping the cutting blade a few millimeters from the cutting line.
Be careful, if you are going to use a glass mirror you will want to leave a wider outer edge to avoid drilling the mirror when making the holes for the screws.
And I touch up and adjust the outer shape with the disc sander and with the drill sanding drum.
And before I forget, a recess has to be milled inside the frame hole. For this, it is best to use the milling table. And with the recess already made you have to check that the mirror will fit into the frame. In this case I will try to make a mirror by polishing a metal sheet, so I adjust the cutter slightly higher than the thickness of the metal.
I can already draw the back of this wooden hand mirror. And just like before, I cut the shape with the jigsaw keeping the cutting blade a few millimeters from the edge of the line.
So, to adjust the shape of this piece I am going to use a copy mill with bearing to make a perfect copy of the front piece. I put the front piece of the wooden mirror, with the sheet metal, on top of the back, and drill guide holes so that I can hold both pieces with decorative screws. I just have to make sure the bit won't come out the other side. And it may also be necessary to widen the holes at the top so that the screws fit smoothly.
I only need the last touches to finish this wooden mirror. I'm going to use a ball-bearing rounding bit to round the edges of the wood frame. I also have to touch up the handle and finally I sand all the wood on this hand mirror well.
I can finally varnish and assemble the pieces of this wooden frame to finish the hand mirror.
See also how I tried to polish the metal for this hand mirror. Something that did not go as well as I expected 🙁: