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Wiffle Ball


Wiffle Ball

By Jock Holmen and Tom Caspar

People ask, “How in the world did you make that weird wiffle thing?” The truth is, it’s really quite simple: it’s just a hollow cube with the corners cut off. Can you figure it out?

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Fasten two pieces of 1/4" tempered hardboard to the sled’s bottom, centered over its slot. Butt the pieces together, then raise the blade and saw through the joint.

Click any image to view a larger version.

Remove the sled and tilt the blade to 45 degrees. For the best results, use a 60-tooth crosscut blade for every cut on this project.

On many contractor’s saws, the blade moves out of square when it’s tilted. Hold a wiffle piece against the blade and fence. Tape a shim to the fence if there’s a gap at one corner. Ideally, you’d re-align your saw to make it cut square, but this quick fix works well for this project.

After the miter cuts, your piece must still be perfectly square. Adjust the shim if your piece isn’t square, then cut four more test pieces.

Drill a 2-1/8" dia. hole in the center of each piece using a Forstner bit. This jig locks in the piece on three sides to ensure that it doesn’t shift. Toggles keep your fingers out of the way.

Turn over the assembly and spread glue on all the joints.

Add the right-hand hardboard piece and two support boards to the sled. Support piece A is 1-1/8" thick by 2-1/8" wide; piece B is 1-3/4" thick by 2-3/8" wide. Cut 45-degree miters on both pieces.

Cut all eight corners to transform the cube into a wiffle ball. Set the blade 3/8" above the sled, then rotate the cube three times, making three cuts, to remove each corner. Finish the ball by dunking it in Danish oil and spraying it with lacquer.

This story originally appeared in American Woodworker November 2007, issue #132.

November 2007, issue #132

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