DIY Network

Display Cabinet -- Shaping Cove Molding, Making Side Panels and Building Frame of the Door From "Wood Works" episode WWK-102

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This visually stunning display cabinet is made with cherry (for the case) and flame-maple (for the back panel) wood. The cove molding at the top of the display cabinet gives the piece an Egyptian flair. Cove molding is basically a concave shape cut into the side of a piece of wood. Many furniture-makers like to create cove molding from individual pieces of wood, but for the sake of efficiency, David Marks -- the host of Wood Works -- decided to combine the cove molding, shaping and top of the display cabinet in one solid block of wood. Figure A Figure B The cove molding for the display cabinet was created by using story blocks (seen here). The story block is essentially a step-by-step guide that shows you how to make the molding. The numbers on the side of the story block tell the order in which the cuts should be made . . . . . . and on the back of the story block you can write the descriptions and setups that need to be made on the table saw. Figure C Figure D

Materials:

2-3/8" thick solid cherry stock
Table saw with fence
Gooseneck scraper
Pencil
Safety goggles

Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Website -- information, below, under Resources.


Safety Alert: Always use safety goggles when working with wood, saws, drills, etc.

1. First, the fence of the table saw should be set up diagonally as seen here (figure A). By cutting across the blade diagonally, you use the arc of the blade to create the curve in the cove molding.
   
   
   
   
2. Using the steps of the story block as a guide, cut out the 2-3/8" cherry stock.
   
   
   
   
3. To cut the cove, raise the saw blade 1/16" at a time and keep passing the wood until it's reached the full height.
   
   
   
   
4. Cut a rabbet groove on each piece by resetting the blade in small increments until the profile is completely cut.
   
   
   
   
5. Set the saw blade at a 30-degree angle to make the first cut of the bevel.
   
   
   
   
6. Move the saw blade over 10 degrees, stand the block against the fence and finish making the bevel (figure B).
   
   
   
   
7. Smooth away the mill marks made by the table saw with a gooseneck scraper, which is made to fit the cove design of this piece.
   
   
   
   
8. Mark the top of the cove molding with a pencil for the following step -- see below -- of joinery biscuit cutting. Be sure your measurements on each side are exact.

Materials:

Biscuit cutter
Side panels of cherry wood
Drill
Double-stick tape
Yellow wood glue
Clamps
Square

1. First, use a biscuit cutter to create the joinery for the cabinet display top, which was just completed. Once the biscuit cutter is aligned (figure C), mill out the slots for the joinery.
   
   
   
   
2. Once the joinery for the side panels is complete, it's time to cut the holes that will hold the glass shelves. It's vital that these holes align properly. David Marks accomplished this by creating a special gig (figure D) that aligns against the side panels perfectly to act as a template for the holes. This is a surefire way to make certain all the reference points for the holes stay the same.
   
   
   
   
3. Place double-stick tape on the bottom of the special gig, position the first side panel and drill the holes. Be sure the depth gauge on the drill press is set appropriately -- you don't want to drill completely through the wood.
   
   
   
   
4. Once the holes are drilled, it's time to glue the cove molding top and bottom to the side panels.
   
   
   
   
5. Brace the glued joinery with clamps. Use a square to make sure the corners are level.
   
   
   
   
6. Let the glue dry.

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RESOURCES :

The Complete Manual of Woodworking
Author: Albert Jackson
Publisher: Knopf
ISBN: 0679766111

Arts and Crafts Woodworking Projects: 11 New Designs in the Stickley Tradition
Model: 0811726622
Author: Robert E. Belke

176 Woodworking Projects: A Workbench Treasury
Model: 0806965282
Author: Workbench Magazine

To order this title from Amazon, click here.

Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985

The Complete Illustrated Guide to Furniture and Cabinet Construction
Model: 1561584029
Author: Andy Rae
(2001)

The Taunton Press Inc.
Website: www.taunton.com

Cabinets and Bookcases (Art of Woodworking)
Model: 0809499452
Author: Niall Barrett

David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com

Handcrafted Cabinetry: Professional Designs: Practical Techniques
Model: 0762101733
Author: Rob Yoder
(1999)

Readers Digest
Pleasantville, NY 10570-0235

Making Wood Handles, Hinges and Knobs: The Perfect Touch for Cabinetry
Model: 0806913355
Author: Alan Bridgewater and Gill Bridgewater
(1998)

Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

The Complete Illustrated Guide to Woodworking
Author: Lonnie Bird, Andy Rae and Gary Rogowski
Publisher: Taunton
ISBN: 1561586021

Furniture Making Techniques: The Best From Furniture and Cabinetmaking Magazine
Model: 1861081251
Author: David Charlesworth
(1999)

Guild of Master Craftsman Publications
Lowes, West SussexBN7 1XU
UK
Phone: 0-12734-78449
Fax: 0-12734-78606

Rodale's Illustrated Cabinetmaking: How to Design and Construct Furniture That Works
Model: 0762101830
Author: Bill Hylton
(1999)

Rodale Press Inc. (Organic Gardening Magazine)
Emmaus, PA 18098
Phone: 610-967-5171
Fax: 800-813-6627
Email: customer_service@rodalepress.com

Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com