Creating the lattice pattern that adorns the front of the Atomic bar can be done it two ways. You can download a CNC file to use with your machine — or follow the instructions shown here. The file and pattern are both available at Woodsmith.com/277.
Make the template. After printing it out to actual size (printing to “actual size” is a critical step) you can attach it to a piece of hardboard with spray adhesive. Then you’ll start by drilling the outer corners with a 1⁄4" drill bit. Next, rough out the shape with your jig saw. Lastly, shape and sand the template to its final size. Take your time with this step — the results are repeated 20 times across the front of the bar. When the template is ready you can start tracing the pattern on the front of the plywood (after cutting the plywood to size). Figure 1 below shows starting in the upper left.
Figure 2 below shows drilling the corners of the pattern using a 1⁄4" drill bit. Using a sharp brad point will make for crisp corners leaving you less clean-up work in the end.
Removing the majority of the waste in the lattice panel is easily done with a jig saw. Remember to stay on the waste side of the line at all times. There’s some strategy involved here — start by removing the waste around the perimeter of the panel (Figure 3 below) then shift positions to support the ends while removing waste in the middle.
To clean up the lattice you’ll bring the template back and use it in combination with your palm router and a short flush-trim bit. Self-adhesive tape holds the template in place. As you finish each section, pry the template free and move on to the next pattern following your layout lines (Figure 4 below).
