I'm a primary school teacher and I'm working on a project involving a self-supporting bridge inspired by Leonardo Da Vinci. I've sourced some broom handles to create the rods needed for the bridge but I'm unsure how to cut the required notches into them. I have access to a power drill and a multi-tool, but I haven't attempted this before. Any tips or advice on how to do this properly would be greatly appreciated!
3 Answers
One straightforward method is to use a sanding drum that fits the diameter of your broom handles. Start by using your multi-tool to create a V-shaped groove, which makes it easier to sand out the notch. If you have a drill press, you can achieve a cleaner result using a hole saw and vice, but that's less feasible freehand. Alternatively, if you get a drill bit that's the same size as the broom handle, drill two overlapping holes in a block of wood to serve as a guide. Don't forget some clamps to keep everything steady!
Don't overlook the power of good old-fashioned sandpaper! Wrap some around another broom handle (with rough side out) and rub it against the one you want to notch. This method is surprisingly effective if you maintain the same angle; plus, it doesn’t require any power tools at all. Just take your time and you'll get the desired notch size without too much fuss!
If you have access to a radial arm saw, that's one of the easiest ways to make those notches! Just tape two rods together so they don't roll as you cut. You can also use a table saw or router table if you're equipped with those. A hand saw is a safe option too - just tape two rods together and mark your notch location. Saw carefully down to the lines, and you can often break out the notches with a hammer if they’re loose enough. A coping saw could help for tighter curves.