OK, to more or less answer, there is no order size, this is strictly a prototype situation right now. The 6 degrees is what looked about right on an Autocad drawing and is subject to change at ay time. It is just a matter of backing off the side to allow working into corners. I'm sure freezing and sawing would work, but knife type cutting methods are attractive from the low dust aspect.
As to history and applications, a while back I found myself working outside of my normal areas of expertise, (whatever that is) and was expected to French polish things like 12' pine planks. The methodology was even more primitive than the old mittens dipped in paint and smeared on cars. What made it really bizarre was that I have a positive pressure spray room with filtered incoming air and good spray equipment that I was not allowed to use because it couldn't be called French polishing. After following orders for a few days, I concluded that the only way to finish the project in a lifetime was to reactivate the slave trade or develop a better method. I made three applicators and found that not only did it speed things up immensely, the unintended consequences were almost all positive.
Right now, I am working on putting together the kit that will cover most shapes and uses. I think the two main targets are people like luthiers who want a very controllable fine finish and home shop woodworkers who do not have access to dust free spray rooms and have the patience to spread the work over a number of days. The finishes i was getting without rubbing out, just as applied, were so tactile that every day as I walked down the isle to my work area, I had to slide my fingers along the finished boards stacked there.
SJ, I am using medium hardness felt from McMaster-Carr. I am not far enough along to be looking at wholesalers.
Steven Thomas, if you are going to be finishing on a regular basis, I could use a beta tester. My PM box is always full, so you can reach me at
[email protected]
Bill