| Contemporary Wall Mirror -- Wengae Accents |
From "Wood Works"
episode WWK-301 |
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With the circular cherry-wood frame for the wall mirror made and fitted with the back panel, it can now be fitted with the classic keystone accents made from African wengae. These keystone accents are classic arch ornaments (figure A). They provide a strong visual impact to the circular frame and focus attention into the mirror. The wedge-styled pieces flare from 3" out to 5" and extend 1/4" on both sides of the frame. They are mounted into notches cut in the circular frame, and sit flush with the mirror. In order to make them, a template is first fashioned out of MDF (figure B). Materials: MDF for template
Wengae stock
Table saw
Miter gauge
Band saw
Plunge router
Yellow woodworker's glue
Clamps Note: Cut sizes may vary. For exact measurements, please contact David Marks through his website -- information below under Resources. Safety alert: Always wear safety goggles or safety glasses when working with power-tools, saws, drills, routers, etc.
Wengae Accents
- To create the recesses on top of the frame joints -- in which the accent pieces will rest -- a router jig is made from MDF (figure C), using the template as a guide. A plunge router and flush-bearing bit is then used to cut a notch 3/16" into the frame.
- Double-stick tape and a stop-block are added to the back of the jig (figure D) to hold it secure against the frame. The stop-block is cut to match the curve of the frame.
- Using the plunge router, route out the recess (figure E).
- Make the cuts in a clockwise motion, slowly notching out the stock (figure F).
- Mill up some blocks of wengae that are 3/4" thick and 5-1/2" wide. The keystones are then cut from the stock, making certain that the grain of the wood runs lengthwise on the keystone (figure G). Most of the inside face of each keystone must be cut away so that it will sit inside the notch on the frame. A lip will hang over the edge of the frame and sit against the mirror.
- Make the first cut at the band saw, with the wengae stock positioned against the fence to make the 4" long cut (figure H). The stop-block ensures that the lengths of the cuts are all the same.
- At the table saw, with the blade raised 1/4", make a perpendicular cut to remove the excess stock, leaving the piece to form the lip at the edge (figure I).
- The flares on the keystones are cut at 19 degrees. When the flares are cut, it's important to make sure that the cuts don't go all the way to the corner of the piece, but instead stop to leave enough material for a 1/4" overhang (figure J).
- The cuts in the wengae stock are made at the table saw using a miter gauge. Set the gauge at 19 degrees off center, and make the cuts on all four pieces with the mitering gauge on the right side of the blade (figure K).
- Next, reposition the miter gauge on the left side of the blade, reset the gauge to 19 degrees in the opposite direction. Then cut the flares on the other side of all four pieces (figure L).
- Once you have one accent piece that fits the frame precisely, flip the frame over with the accent in place. With a compass set to 1/4", scribe a line on the accent piece to make the trim cuts for the overhang.
- At the band-saw, fine cut the curved overhang to 1/4". When cutting dark wood like wengae, it's a good idea to add some colored carpenter's tape to highlight the cut (figure M). Once all four are cut, use some fine sandpaper to soften the inside and outside edges of the accents.
- Before gluing on the keystones, use a plunge router and 1/8" radius bit to round over the edges of the frame (figure N).
- Use a scraper and some fine sandpaper to finish the fine cleanup of the frame.
- Use yellow woodworker's glue, applied in the notches and accent pieces, to glue up the assembly (figure O).
- Clamp the assembly securely and allow the glue to dry.
- In the segment that follows, the final assembly is completed and a tung-oil finish is applied.
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
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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