DIY Network

Dovetail Bench: Shaping and Sculpting the Seat and Legs From "Wood Works" episode WWK-602

	In this segment, the raw block-form of the newly assembled bench components are hand sculpted to provide gracefully sweeping curves.
	The angle grinder and arbortech blade are used to begin sculpting the curved surfaces.

In this episode of DIY Wood Works, host David Marks builds an Egyptian-inspired bench made using dovetail joinery. In this segment, the seat and legs of the dovetail bench are shaped and sculpted using a variety of power and hand tools.

Materials:

MDF for templates
Band saw
Variable-speed disc sander
Random orbital sander
Angle grinder and arbortech blade
Microplanes
Rasp
Sandpaper
Safety glasses or goggles
Gloves
Ear protection

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

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Shaping and Sculpting

• As seen on the prototype (figure A), the seat top has a gentle sweep for comfort while the sides complement the arc of the top with an elegant curve that provides strength as well as the Egyptian motif. The design also includes a curve at the foot.

• To fashion the curves, three templates were fashioned out of 3/8" MDF (figure B).

  Figure A

  Figure B

  
  

  
  
  

• The curve on the top and legs is traced onto the stock using the curved templates (figure C). The smallest template is attached to the bottom of the leg to trace on the curved footprint.

• With the curves traced onto the stock, the shape can be roughed out using the band saw. This was possible by raising the blade guard and guide assembly on the band saw to the maximum (highest) setting. We also clamped an extension onto the band-saw bed to support the structure.

• Following the line of the template, carefully rough cut the excess material on the top (figure D) and both sides.

  Figure C

  Figure D

  
  

  
  

• The next phase of the process employs some hand-held power tools to sculpt the curves. For the top and sides, we used an arbortech blade mounted in a standard 4-1/2 inch angle grinder that spins at 10,000 rpm. The arbortech disc is comprised of three sharp blades that rotate at this very high speed and remove wood very quickly.

• The heavy sculpting action of the blade removes the bulk of the wood on the top and sides quickly. Follow the layout lines as you make smooth, even passes across the surface (figures E and F). Use caution as you use this high-speed tool to avoid removing too much wood.

  Safety Alert: When using an angle grinder, exercise extreme caution, and wear goggles, gloves and earplugs.

  Figure E

  Figure F

  
  

  
  

• Next, use a variable-speed disc sander, with 24-grit sandpaper, to blend the surface of the seat (figure G).

• Sand the top, then use a ruler to confirm that the sanding is to the desired depth.

• Use the same tool to sand the surface of the sides (figure H).

  Figure G

  Figure H

  
  

  	Figure I
  	Figure J

  
  

• Hand tools such as microplanes and rasps are then used to help visually blend the union of the two curves at the inside corners (figure I).

• Microplanes are excellent tools for removing stock quickly and shaping inside curves, and come in various configurations. We also used a #49 and #50 to blend the curve.

• Next, use a random orbital sander (figure J) to blend all of the marks left by the previous tools and make a uniform surface. Start with 36-grit sandpaper, and gradually move up to 100-grit.

• Finally, hand sand with 120-grit, followed by 220-grit, to make a silky-smooth surface. Then raise the grain by spraying on some water, let it dry and sand to 320-grit in preparation for the finish.

RESOURCES :

Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456

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

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com