This mission begins out with a extremely twisted board. On this case it gained’t matter a lot as a result of the a number of smaller items that I want can have a manageable quantity of twist in them. However I believed it will be attention-grabbing to point out simply how dangerous of a board you possibly can work with for those who put it to use the suitable method. This board is 12” large, just a little greater than an inch thick, and the twist proven right here is thru 8′ of the board.
First up is to structure for the tough cuts. I laid out my items based mostly upon the quantity of twist reasonably than attempting to maximise the usage of the board.
The board is clearly too twisted to securely lower with the miter noticed so I took it to the workbench to chop it by hand. Utilizing a round noticed or a jigsaw would have been a lot sooner however I keep in mind I used to be just a little chilly and sluggish that morning. I additionally keep in mind one morning my mother was complaining in regards to the chilly proper after beginning a fireplace within the wooden burning range and my grandpa advised her “lower your personal firewood and also you’ll heat up twice.” This specific piece of mahogany wasn’t firewood however chopping it by hand did heat me up a bit.
The remainder of the milling course of is fairly typical. First, ripping some additional materials off on the bandsaw..
Jointing one large face on the jointer…
And planing the other face flat and parallel with the planer.
Now the templates might be traced to the mahogany so we all know how a lot additional materials must be eliminated earlier than sample routing.
For the waste removing I began on the bandsaw. I’ve had this bandsaw for a 12 months and a half now and since day 1 I’ve had this 1” carbide tipped resaw blade put in and have by no means taken it off. It’s an absolute beast for resawing large hardwoods, which makes it a extremely dangerous alternative for chopping curves.
To take away much more materials and get it nearer to the road I switched to the jigsaw.
Now the fabric is shut sufficient to the form of the template for sample routing. There’s a number of other ways to safe the template to the fabric however I favor nitto tape, which is the best double sided tape I’ve ever used.
Clearly a flush trim router bit is critical for this to work. Right here I’m utilizing a 1/4” diameter downcut spiral bit with a bearing (Whiteside RFTD2100. Use code JAYBATES15 to get 15% off at bitsbits.com). This measurement bit is sufficiently small that it might get into tighter areas in comparison with a bigger flush trim bit. The draw back is that it solely has one bearing location so that you’re pressured to chop in a single path. This implies you may be chopping uphill in some circumstances and may get some tearout. For the facet items I used solely this bit to see how a lot tearout would occur. It wasn’t an incredible quantity but it surely was there in some locations.
However for essentially the most half, the surfaces have been excellent.
Then every part will get a roundover. I’m utilizing a 1/8” radius roundover on all the sides, besides the place the deal with will go. This small radius will permit the joinery to seat flush with out utilizing a chisel to sq. the within corners of the joint.
As a result of radius of the bearing the roundover bit cant fairly make all of it the way in which into the within corners. Some mild contact up work with a rasp and sandpaper is required for these corners. The alternate strategy is to not use a roundover bit contained in the joints and simply chisel the tiny little bit of waste within the inside corners to make every part sq..
Typical of Greene and Greene furnishings, the field joints shall be held in place with screws, which is able to then be coated with ebony sq. plugs. I’ve by no means finished this earlier than so it is a first for me. With the fence and depth cease set on the drill press I drilled pilot holes within the middle of every finger.
From there a sq. punch might be positioned with the assistance of a drill bit within the gap and a sq. to maintain every part in line. I used a 5/16″ square punch from Lee Valley. The bit is eliminated and a hammer is used to drive the punch till it strains up with a depth cease line on the punch. After which the drill might be reinserted to take away a number of the waste with out making the outlet deeper. Rinse and repeat for the entire screw holes.
With the entire panel holes finished I gave every part an total sanding with 180 grit sandpaper. It’s a lot simpler to get a good sanding like this earlier than meeting.
Glue can even be used for meeting. Particularly, epoxy. Crucial factor when utilizing epoxy is to verify it’s combined correctly. To assist with that I all the time set a 2 minute timer whereas mixing. Additionally, the screws I’m utilizing have a extremely small head to them so that they gained’t harm the sq. gap when driving them in.
Just a little little bit of epoxy within the joints and the screws are pushed dwelling. After all, the screws will pull the joints tight in a single path so a clamp is simply wanted in the other way.
The subsequent morning I began by milling a board for the deal with ensuring it was as shut as I may get it to the ultimate thickness with out really becoming within the deal with slot. The ultimate match shall be achieved when sanding.
I didn’t have a protracted sufficient piece of the unique mahogany board to make the deal with so the colour match isn’t excellent. However one benefit of this piece is that the grain has a curve in it much like the form of the deal with. Any time you should use the pure form of the wooden to imitate the form you want the ensuing piece shall be stronger and extra visually interesting.
Again to the bandsaw to tough out the deal with. This form was straightforward sufficient to tough out utterly on the bandsaw.
For the deal with I wished to point out a unique strategy to the sample routing and that’s to make use of a larger flush trim bit with both a top and bottom bearing in order that your entire piece might be routed within the downhill path. First the bit peak is ready in order that the highest bearing contacts the template on prime of the wooden.
Then the entire downhill chopping is accomplished ensuring to not go within the uphill grain path..
Then the template and materials are flipped over so the template is on backside and the bit peak is modified in order that the underside bearing is used..
After which the remainder of the routing is accomplished ensuring to go within the downhill path as soon as once more. The outcome needs to be a 100% tearout free lower.
As a result of this deal with template is a 3 piece meeting I don’t advocate pulling the template off of the wooden. As a substitute, use a putty knife to slice away the double sided tape. This may scale back the stress on the template joints and can help you use the template again and again.
The deal with will get the identical roundover remedy as the opposite items..
And extra sanding to finesse the form and the ultimate thickness to suit tightly within the deal with slot.
The ensuing match needs to be actually tight and because of the path of the grain on the facet panels there shouldn’t be a threat of something splitting.
With the deal with stress match and never transferring the sq. gap course of is repeated on each side. I didn’t connect the deal with with epoxy and screws at this level as I wished to take away the deal with when putting in the ebony plugs within the sides.
Subsequent up is the ebony plugs. To get began a block is jointed flat and perpendicular on two adjoining faces. Then a sq. clean is ripped about .010” greater than the dimensions of the outlet punch I used.
Off digital camera I went although your entire course of on a check gap. Not too shabby for the primary strive so I went forward with the precise items.
As I mentioned, I’ve by no means finished this earlier than. So I seemed up a number of movies on the method and the technique I went with was from William Ng. Mainly a sequence of sandpaper with padding beneath to permit a slight pillowing of the highest. The ebony stick is chucked right into a drill and whereas retaining the ebony vertical the entire grits are used. I additionally used a leather-based strop with compound on it for sharpening.
Each ends on every stick have been pillowed earlier than chopping them free.
After getting sufficient plugs lower all of them acquired a slight chamfer on the underside edges with a chisel. This may permit the plugs to be wedged tightly in place and stop damaging of the outlet because the plug is hammered in.
Glue, plug, hammer. Over and again and again and over.
Lastly the deal with is epoxied and screwed into place. After which the ebony plugs are added the identical method.
There’s quite a lot of completely different choices for the underside panel. To maintain with the theme of strong wooden I opted to go along with a random shiplap panel. To start out, a 3/8” sq. cleat was milled and secured to the within of the panels simply with glue.
Then a bunch of scraps have been resawed and milled to three/8” thickness..
After which a rabbet was lower on every on the router desk. Ensuring to flip the board on the quick path to type the alternating face of the ship lap. Mainly it’s simply two rabbet joints that can overlap each other.
With the joinery finished we lower the entire slats to the identical size on the miter noticed and ripped the final piece to it’s remaining width on the desk noticed. The primary fringe of the primary piece and the final fringe of the final piece must be flush and never have the shiplap rabbet lower on them.
For set up I used a bead of glue all alongside the three/8” cleat and glued each bit down. These are particular person items and never a strong panel so I can get away with gluing them in place. The ensuing glue joint is about the identical measurement as a typical rail and stile joint in a cupboard door so I don’t see any points there. And the shiplap joint between the slats creates a steady floor with no gaps. Then one thing heavy is added to carry every part down whereas the glue dries.
The subsequent day I prepped for ending by sanding and vacuuming to take away some ebony mud…
And sprayed the end outdoors. It was fairly chilly that day so I instantly introduced it again inside after spraying.
On this case I simply began the ending course of. Finally I’ll add both a number of extra coats of shellac adopted by a scuff sanding and wax or only a coat or two of satin polyurethane. Ether method, I didn’t need to utterly end it simply but so I can nonetheless simply scuff the floor and glue device holders inside. After I get the entire instruments and holders positioned I’ll full the end.
If you wish to make considered one of these as nicely then take into account choosing up a set of the templates. The entire design work is finished with the templates so that you simply lower out the items and finesse all of the effective effective particulars. And naturally, it is a field so it may be used for lots extra than simply instruments.