In anticipation of receiving the assembly for Rubber Band Gun #6 from Dixon Tool and Die, Inc., we have been making a new rubber band gun stock to complete the package.
This stock was hand crafted out of solid 1.75″ x 6.0″ x 48″ slab of maple. The primary tools were bandsaw (for the profile), hammer and chisel, random orbit sander, end mill, jointer, sand paper, and lots of elbow grease.
There is a technique that we implemented called “raising the grain”. It involves rubbing the wood with a wet rag, and then letting it dry. Loose pieces of grain swell up and in turn raise up out of the wood, where they can be sanded off.
At the bottom-left corner of this photo, you can see another blank ready to be cut.
A lot of thought and testing went into this simple design and it works really well. The catch (no pun intended) is to allow the rubber bands to release cleanly with no interference.
Here is Mr. E holding the shop-vac to keep the end mill from clogging up. My Sherline milling machine is not large enough to hold this stock conveniently, so we used a drill press and cross-slide vice to mill it out. Drill presses are not as rigid as milling machines, so we had to take it slow.