C. C. Crow Stone Church - First Annual Raymo Build Challenge 2016

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Before I get started on the cutting process here is the label from the Smooth-On plastic that I used for this casting.  I'm really happy with this product.  This is my third batch of it and so far it works great.

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Here is the product numbers and specifications if you want to try it.

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The first step in fixing the castings was to sand down the bottom step to a even 8 inches HO all the way across
the casting.  I used a digital micrometer to monitor my progress until I got it where I wanted it.  0.092 inches is a scale 8 inches.

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Here is a side view of the casting when I was getting close with the bottom step. You can see how out of scale the three upper steps are at this point.

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Next it was time to get out the jewelers saw - a very small thin bladed coping saw. 

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Here is a picture of the cutting process as I got started.

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Note: At this point I was trying to keep to the Bob Butts standard of build threads and show you the cutting process while I was doing it  with my hands doing the work etc. etc. Well, as I snapped this picture with the camera in my other hand I broke the blade on the jewelers saw. Challenge number 2.

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Here is a second picture, yes it's overkill but these pictures cost me a saw blade.

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I know now the Bob is mounting his camera on a tripod and pushing the shutter release with a remote on the floor with his foot.  Right Bob?

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So after replacing the blade - I made my way around the corner and was making good progress when I got the bright idea to take another picture.  Broke the second blade.

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So from here on out you are getting pictures at the end of each step.  Here we have the first casting piece ready to be sanded to proper size.

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Here is the master casting with that block removed.

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Here is the master casting after the next block or step is removed.

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Here is the four pieces of the casting ready to be cleaned up and sized. Yes - I finished the process with a smaller second blade.  Notice the pieces of blade on the workbench.

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Each step had to be sanded down from the back side until it was 8 inches HO higher than the previous step. I did this with a piece of adhesive backed sand paper mounted on my workbench.