| Oak Step Ladder -- Steps |
From "Wood Works"
episode WWK-205 |
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Building the Steps With the side panels cut out of oak stock, and the dado joinery made, the next phase of the project involves making the steps. The steps are made from the same quarter-sawn white oak as was used for the sides. They are trimmed with 3/4-inch Honduran rosewood. On the ends of each step is an angled tenon (figure A) that will join with the corresponding dado on the side panel. A full-scale front-view drawing was made of the ladder's profile (figure B) to help get the measurements for the joinery.
Materials: Table saw
Table router; spiral carbide bit
Yellow wood-glue
Slow-setting glue
Clamps
Straight-edge
Carpenter's pencil
Carpenter's tape
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc.
Steps:
- Place the step stock on the drawn template to make the layout marks where the steps join the sides (figure C) for cutting the shoulders. Make the layout marks for all four shoulders. By connecting the marks, the 8-degree angles for the angled tenons are created.
- With the table-saw blade raised to 1/8-inch, and tilted 8 degrees, make the angled cuts on the face of the step stock (figure D).
- Then, flip the stock over the blade and make a matching 8-degree cut on the back side.
- Next, make the 8-degree cuts on the other side of the step stock. Repeat this process for both steps.
- At the router table, clean up the shoulders of the step stock (figure E) using a spiral carbide bit raised to 1/8-inch.
- Then at the table saw, with the blade set to 90 degrees, trim the sides of the step stock to length to create the tenons (figure F). The tenon is cut to 3/8-inch (figure G) -- the depth of the dado made earlier.
- To finish the tenons, cut a haunch on the back of each step using a hand saw (figure H). Each is cut to about 1/8-inch deep (figure I). Once the steps are installed, the haunches will conceal the dados in the side panels.
- With the tenons and haunches cut, set the tenons into the dados to ensure a snug fit.
- Once the steps have been dry-fit to ensure that everything fits and lines up properly, the Honduran rosewood trim can be added to the front of each step. The trim will extend out past the sides of the steps slightly to conceal the joinery. With the steps in place, scribe some lines (figure J) to indicate how much wood to take off of the fronts of the steps so they'll sit flush with the sides.
- With the table-saw blade set at 20 degrees (the same angle as the front of the side panels), make an angled cut along the leading edge of each step (figure K ).
- Mill up the rosewood stock for the trim on the front of each step. Note that the top step is a simple step designed to overhang the side panels 3/4-inch on all sides. It doesn't require any dados as it's attached simply using screws and glue. The rosewood cap on the top step is attached at a 90-degree angle (figure L). By contrast, the rosewood caps on the lower steps are attached at a 20-degree angle to match the slope of the front (figure M). With the saw-blade set to 20 degrees, the strips for the lower steps are cut first. The angle on the blade is then set back to 90 degrees to cut the strip for the top step.
- To cut the trim stock for the lower steps, cut a 20-degree angle on one side (figure N).
- Then, cut a 90-degree angle on the trim for the top step.
- Using yellow woodworker's glue and a glue roller, glue the caps onto the steps. Because the caps on the lower steps are angled, there may be a tendency for the caps to slide during glue-up. To counteract that, clamp them on the sides to create downward pressure that will hold them flat against the assembly table (figure O).
- Once the caps are dry, remove any excess glue and rip a straight cut on the table saw (figure P) to leave a 3/4-inch reveal along the top.
- With 3/4-inch of rosewood trim on each step, cut the ends of the trim to proper dimensions on the table saw (figure Q).
- At the router table, round the edges of the trim (figure R), making certain to shape only the top and bottom edges -- not the sides (figure S).
- Finish each step by sanding the back edge smooth using a fine-grit sandpaper.
In the segment that follows, the ladder is assembled.
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RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
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
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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