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Biscuit Mortises and Gluing

Host Amy Devers continues the contemporary bench project by creating and using biscuit mortises.

From "Freeform Furniture"
episode DFFF-208

The second phase of the Freeform Furniture contemporary bench project involves aligning the boards for the seating by using biscuit mortises cut with a biscuit joiner.

The wood is cut down to size on the table saw with the cross-cut sled, and the seating area is defined by gluing on decorative pieces with yellow wood glue. Finally, cauls are utilized to evenly distribute the pressure while the pieces are clamped with some small-bar clamps.

The room before—before

The room after—after

Amy Dever's contemporary creation looks great under any lighting conditions.

This unique bench is the definitive definition of freeform furniture.

Amy Devers continues the contemporary bench project by creating and using biscuit mortises to glue the wood pieces together.

Figure A

Figure B

Figure C

Materials:

solid poplar
water-based casein paint
lacquer
rectangular steel tube
chrome plated
nine separate pieces lumber
pre-surface lumber
glue
clamp
scrap pieces of plywood as cauls
bar clamps
biscuits
pencil
yellow wood glue
plastic credit cards
glue scraper
decorative pieces
cauls
flush trim bit
chamfer bit
dusk mat
sanding block
high-pressure air hose
soft bristled brush
water
lacquer
satin spray lacquer
respirator
mild steel tubes
screws

Tools:

joiner
planer
combination square
table saw
biscuit joiner
square ruler
crosscut sled
random orbital sander
router
abrasive cut off wheel
disc sander
vice clamp
TIG welder
awl
mallet
power drill

Biscuit Mortises and Gluing

Once all the wood is surfaced, take it and clamp it together to make sure it'll fit together without any gaps. Use bar clamps (figure A) because they have adjustable jaws that are great for holding large pieces like these together.
Make sure to alternate the grain pattern (figure B). If they were all oriented the same, there would be a tendency for the wood to warp or cup. If you alternate them, it will help balance out the pressure and keep the board level.
Use scrap pieces of plywood as cauls. Cauls do a couple of things—they help evenly distribute the clamping pressure and they also help prevent the clamp from dinging the wood (figure C).
The great thing about a long grain to long grain glue joint is that it is a really structural joint in itself. You don't actually need any kind of joinery. Use biscuits to help keep everything aligned during the glue up.
In order to use biscuits you need to cut biscuit mortises. You do that with a biscuit joiner. It has a tiny, little circular saw blade and when you press the blade into the wood, it cuts a crescent-shape slot for the biscuit.
Mark out where you want the biscuits to go. Before disassembling the dry clamp, use a square ruler and a pencil to mark both sides of each biscuit joint.
Line up the biscuit joiner with the mark and cut in the slots.
Apply yellow wood glue along the edges of the wood you want to join together—and then spread it into a nice even coat with the credit card.
Tip: The fake credit cards you get in the mail all the time are great to use for spreading glue.
Insert the biscuits and then join the pieces together and make sure to line the joints up properly before tightening the clamps.
Once the three pieces are connected, secure them together with bar clamps. Wipe the excess glue off the surface area and then wait four hours until the glue dries.
When the glue is dry, scrape off some of the glue that seeped out of the joint with a glue scraper.
Cut it down to size on the table saw with the crosscut sled.
Give it a quick sand with the random orbital sander. Smooth out any minor inconsistencies that might be there from the glue up.
Define the seating area by gluing on the decorative pieces. Apply the decorative pieces using the same techniques used to make the main seating area, and then cut them to size and put a 45-degree angle on them.
Use yellow wood glue to glue them in position. Sand the bench down, apply glue to the decorative pieces and spread it into an even coat with the credit card.
Use cauls to evenly distribute the pressure, and clamp the piece together with some small bar clamps.
Install a flush trim bit on your router and trim off all the excess material all the way around both sides of the bench.
Use a 45-degree chamfer bit and put a nice decorative chamfer on the bottom edge of both sides of the bench. And then, use an 1/8" round over bit and put a nice profile on all the crisp corners.