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Put the first layer on your bench in order and apply glue. Place the plywood face on top (photo 11) and secure it to the layer pieces with small brads.

Photo 11-Glue the plywood face to the first layer and hold them together with small brads.

Turn the assembly over, then glue and nail the successive layers in place (photo 12). Keep all pieces as closely aligned with the outer edge of the plywood as possible.

Photo 12-Glue the other layers together successively, attaching each piece with nails.

When all pieces are in place, clamp the whole assembly (photo 13). Be sure to place a clamp over each of the staggered joints.

Photo 13-Clamp the assembly together, and be sure one clamp gets located over each staggered joint.

When out of clamps, power sand the edges of the guard at a stationary belt sander or with a portable belt sander (photo 14).

Photo 14-Sand the edges smooth once the guard is out of clamps. You can do this with a hand belt sander as shown, or with a stationary sander.

Custom design a mounting bracket to fit your machine. The guard must be easily removable, so attach it with wing nuts fitted onto combination hanger bolts which have wood screws on one end, and bolt threads on the other. To attach the bolt, put a wing nut on it and turn the wing nut down to the bottom of its threads. Grab the wing nut with locking pliers and screw the bolt into its pre-drilled hole (photo 15). Once in position, give the pliers a sharp rap in the opposite direction to loosen the nut from the bolt.

Photo 15-Secure the guard to the machine with a customized support bracket. Use hanger bolts with wing nuts to hold the guard to the bracket.

Locate the holes in the guard face by holding the guard in position with its inside face against the projecting hanger bolts. Check to ensure that the clearances around the pulleys are uniform, then strike the outside face of the guard with a hammer in the area of the bolts. This will cause the bolts to dent the inside face, showing you where to drill your holes. Cut notches in the guard walls to clear any obstructions, then seal the wood with an oil finish at least, or paint with a suitable color.