From beginning to end it was a freaking nightmare. It ended up in the bin once!
The exact dimensions have to be nailed from the start before glue up to less than a mm accuracy.
Cutting the trapezoid shaped sticks was the easiest part but glueing them together to make the triangle was problematic as the clamping pressure pushes the 3 elements away from each other. Multiple jigs were required.
When assembling the pieces all of the small errors started to compound and lining up the pattern became virtually impossible. I had to dis-assemble it several times and build another jig to allow me to trim every piece to a consistant size.
Glue up to the substrate had to be done in many steps as the pieces would move under the cauls if I tried to glue too many. I found this out the hard way.
