After playing around on our wheel a bit, we weren’t thrilled with the plaster bats we made. So I made a couple of square aluminum bats with some scrap pieces of metal. They work well but not really a cheap way to go to make lots of them. I tried making some out of masonite but they warp badly. We had a stack of corian pieces we got from a friend that does kitchen counter installations that had been sitting around for years so I routed a test one and it was great. So I cut a stack of them. I plan to use one of these for the wheel head for our second wheel. The corian bats are perfectly flat, will not warp and are extremely durable.
Here’s what the bats look like after routing. Using a router instead of a jigsaw lets you use a circle template to get perfectly round bats.
Screw the circle cutting jig to the corian.
Starting the routing .
Circle complete. I made two passes, one cutting half way through then all the way through.
Bat removed from sheet after cutting.
You end up with a perfect circle and a hole in the exact center. I have a bat pin template that I attach using the hole in the bat and drill the two holes ten inches apart.