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When ever I start some kind of a different woodworking project that I have never attempted before, I have learned that making a prototype or working model of the object is a great way to learn about how to build it. And this is the case with making Sunglasses. I have never attempted to make sunglasses with wooden frames, but have always wanted to do do this. I have seen them - rarely - so I know it can be done but have no idea what the pitfalls might be. The first thing I need is lenses and the quickest and easiest place for me to acquire sunglass lenses is ... you guess it one of the Dollar Stores. I picked out a pair of sunglasses, that looked to me, like they would be something I could work with. Fairly flat lenses 9or so I thought) and not fancy. Something actor Jack Nicholson would wear - how could I go wrong with that?
I had given this project a fair bit of thought and I theorized that I could pop the existing lenses out of the frames, then use the frames as a template to make the new wooden frames. It all worked in my head, too bad it didn't quite work in practice.
After spending a couple of hours making a jig to hold the sunglass frames, which I would then use a patterning bit in my router table to easily make the inside of the frames, I had made myself a beautiful jig that anyone would be proud of ...