Step 11: Ease the outside edges of the trivet with a 1/8-in. Or, you could smooth the broader curves on a disc sander, then switch to sandpaper wrapped around a dowel to finish the inside curves next to the trivet’s stem. The Dremel Trio makes this task easier, because it comes with a small sanding drum accessory and sanding sleeves (see Photo 6). Peel the paper off, and wipe it with more solvent to remove any residual glue. One easy way to do this is to soak the surface with mineral spirits, which will soften the adhesive.
Step 9: Remove the template pattern and sand the trivet’s face smooth. Step 8: When the glue cures, unclamp the assembly and cut out the trivet on your band saw or scroll saw (see Photo 5). Use a piece of scrap sheet stock to act as a caul for pressing the template down uniformly (see Photo 4). Glue and clamp the template to the bottom walnut lamination. Step 7: Spread a thin layer of glue on the back of the template blank, stopping the glue short of the cutout areas. When those are finished, raise the bit to 1/8 in., and rout the pumpkin’s shallow groove details (see Photo 3). Work slowly and carefully to keep these deep cuts on course. Once these areas are defined, raise the bit so it’s only cutting about 3/16 in. Clean away the rest of the waste from the cutout areas, working up to the layout lines. Step 6: Switch to 1/8-in.-diameter straight or spiral bit, and set the cutting depth to 5/16 in. “Rough out” the eyes, nose and mouth now.
Rout away the waste carefully, leaving a little waste next to the template layout lines (see Photo 2). Start the tool, and slowly plunge the bit down into the middle of the first cutout area with the edge of the base held firmly against the template. straight bit in your Trio or trim router, and set the cutting depth to 5/16 in. Clamp the backup board to your workbench. If you use the Trio or a comparable trim router, mount your template blank to a piece of scrap MDF or other sheet material with pieces of double-sided tape to help minimize tearout on the bottom face. For this project, we’ll be using Dremel’s Trio tool, which looks like a jigsaw but functions like a trim router. Step 4: There are two machining options for cutting out the eyes, nose, mouth and eyebrows of the Jack-O’-Lantern: a scroll saw or a router. Use a J-roller or a soft cloth to press the paper firmly into place. Step 3: Affix the paper template to your 1/4-in.-thick top blank with spray mount adhesive. You’ll want to keep the base of the router stable as you work. Select blanks that are about the same size as the template sheet to give you plenty of room to work when routing the face details. Step 2: Prepare two wood blanks for the project, planing them both to the correct thickness.
Step 1: Download and print out a copy of the PDF Jack-O’-Lantern Trivet template attached to this article. Select a dark hardwood such as walnut for this layer. A 1/2-in.-thick bottom lamination creates a sturdy base while it accentuates the cutout features.
A neutral-colored, blonde hardwood such as beech, maple or birch works well for this layer-especially if you dye it orange as we do here. The 1/4-in.-thick top layer with routed details forms the trivet face.
It’s made of two contrasting layers of wood. Whether you’re dishing devilishly spicy cheese dip or some steaming witches brew, this two-tone Jack-O’-Lantern Trivet will help keep hot serving ware from damaging other surfaces. Here’s a Halloween project that’s just right for serving hot party treats.