Cutting cushion ends.

[cycopath]

I know most guys recommend using soapy water as a lubricant. My question is, do you cut in one swipe, or make a few cuts off the end of the cushion until you are at the desired length? I'm just scared of not having my angle right if I take one big cut off the end.

 

[TheTablePro]

I know most guys recommend using soapy water as a lubricant. My question is, do you cut in one swipe, or make a few cuts off the end of the cushion until you are at the desired length? I'm just scared of not having my angle right if I take one big cut off the end.

I've used Windex on a sharp knife for eons. If you set the rail up so the nose of the cushion is on your bench or cutting surface, lay the knife up against the subrail and just follow the factory profile of the subrail. That should make the correct cut of the new cushion. To finish out any imperfections in the cut, I use a neumatic disc sander to smooth them out perfectly with the subrail profile before putting on the facings. (some techs use belt sanders which works perfectly as well).

Take your time and you'll do fine. Good luck!

Robin

 

[cycopath]

Used your advice, and it worked like a charm!

Thanks again Robin.

One more question. What grit sandpaper do you use to do final shaping, with the Air D/A sander?

 

[TheTablePro]

The disc is about a 100 grit. Whatever you have should work though. You're just flushing them up while saving the factory cut of the subrail as the guide. They will be smooth so the facings glue on easily.

Let us know how you make out.

Robin