| Contemporary Magazine Rack -- Curved Laminate Legs |
From "Wood Works"
episode WWK-207 |
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Curved Laminate Legs Once the curved leg stock has been created by bending laminated walnut strips, the next phase is to cut the leg stock into the finished legs, clean up the edges and prepare the legs to accept the brass-dowel connectors. Materials: Bent-laminate leg stock
Belt sander
Jointer
Band saw
Drum sander
Drill press; Forstner bit
Japanese hand-saw
Compass
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: - Once the glue has dried on the walnut-laminate leg stock, the clamps can be loosened from the bending form and the curved stock pieces removed (figure A).
- With the leg-stock removed, use a belt-sander to remove the dried glue from one edge of the stock. The resin glue dries very hard, so it's best to remove the glue to avoid damaging the knives of the jointer.
- With the excess glue removed, pass one side of the leg over the jointer (figure B), following the arc of the curve, to produce a flat edge.
- With the flat edge against the fence at the band saw, cut the legs to proper width (figure C), producing two legs.
- Using the first cut on the second leg as a reference, trim away the remaining glue on the outside edge (figure D).
- Next, go back to the jointer to joint one edge of the second leg (figure E ) to get a flat surface.
- Then, run each leg through the drum sander (figure F) to produce a flat and parallel surface on the opposite edge.
- Use the template made earlier as a guide for cutting all the legs to the same length. Lay the curved template on the edge of the leg, mark a line using a pencil (figure G) and transfer the line all the way around the leg.
- A useful tool for trimming the laminate legs to proper length is a Japanese hand-saw (figure H). The teeth of this specialize saw gradually get smaller from top to bottom, and yield a smooth edge when cutting a laminate (figure I).
- In the finished rack, the magazines will hang from 1/4-inch brass rods glued into holes on the insides of each leg. In order to ensure that none of the hanging magazines touch the floor, the first brass rod will be set at 9-1/2 inches above the floor. A compass is used to mark the locations for the holes on the template using the layout marks on the full-scale design as a guide. (You'll then use the template to mark each curved leg for the locations of the holes.) To get the initial measurement, square up the template and measure up 9-1/2 inches from the bottom. Then, use the compass to measure 3 inch intervals between each hole, and make a mark to indicate the location (figure J).
- To mark the positions onto the leg, secure the template onto edge of the leg with masking tape to prevent slipping, then drill a pilot hole at each marked location with a 1/16-inch bit (figure K).
- With all of the pilot holes drilled, take the leg to the drill-press and use a 1/4-inch Forstner bit to drill holes 1/2-inch deep (figure L). (A Forstner bit makes a clean cut, and reduces the chance of chip-out when drilling laminates or other delicate pieces of wood.)
Repeat these steps to create the second pair of legs. In the segment that follows, the joinery is made for the legs and stretchers.
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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
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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