| Contemporary Walnut Bench -- Base Form and Mortises |
From "Wood Works"
episode WWK-303 |
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In this episode of DIY Wood Works, host David Marks builds a contemporary walnut sitting-bench with a patina-copper base. This bench is a solid and functional piece of fine-art furniture with a creative and contemporary flair. It features a seat made from a 5-foot slab of solid walnut, sculpted-walnut support-posts and base supports veneered with copper that's treated to give it an aged patina (figure A). The unusual construction of the bases offers some interesting design challenges.
Base Forms and Mortises The base for the bench is actually two boxes that have been made from 3/4-inch plywood. They are attached at the top with mortise and integral-tenon joinery. Rather than cutting a mortise in a solid-wooden box, in this case the mortise is actually built into the structure of the box using layers of cut plywood (figure B). The mortise structure is actually a single composite piece that fits down inside the plywood box (figure C). Each mortise is composed of 9 plywood elements, some of which are 3/4-inch thick and some 1/2-inch thick. The elements are glued and nailed together.
Materials:
3/4-inch plywood
1/2-inch plywood
Table saw; cross-cut sled
Nail gun; finishing nails
Belt sander
Yellow wood-glue
Glue brushes
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:
- Start by cutting the plywood stock. At the table saw, rip the plywood stock to the various widths needed to make the bases and mortises. Begin by cutting the 3/4-inch stock for the side faces of the two bases.
- Next, rip the stock for the narrower sides to the base.
- Cut each plywood piece to the proper length using the cross-cut sled on the table saw.
- Using the cross-cut sled, cut the smaller pieces that will make up the mortises (figure D).
- With all the plywood elements cut to the proper dimension, begin gluing up the boxes. Start by gluing together the mortises. Brush on a light coat of yellow woodworker's glue and align the first two small pieces, and drive in a few finishing nails using a nail gun (figure E).
- Apply glue to the top of that stack, align the last piece and drive in some more nails.
- Repeat these steps to create a second stack.
- Next, brush some glue on one of the mortise side-pieces, align the plywood stacks, and secure the side piece with nails.
Important: Since the inside of the mortise needs to be kept clean for a proper fit with the sculpted posts that will be added later, apply glue only to the connecting surfaces.
- Repeat the steps for the second mortise side-piece, securing it with nails (figure F).
- Finally, attach the bottom piece in the same fashion (figure G) to complete the first mortise.
- Repeat these steps to create a second identical mortise.
- With the mortises complete, the base assembly can begin. To assemble the base, first position the mortise onto one of the side faces, add glue, and then glue the bottom and narrow sides together to form a box (figure H). Use the nail gun to secure the pieces of the structure in place.
- Apply glue to the assembly, and to the opposing side face (figure I), position the side-face and secure with nails.
- Flip the assembly over, position the final side (figure J) and secure it with glue and more nails.
- Repeat the steps to create a second identical base structure.
- Once the glue in the base structures has dried, use a belt sander to clean up the edges and remove any excess glue (figure K).
In the segment that follows, a copper veneer is created for the base pieces.
Sponsored Resource
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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
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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