| Walnut Coat Rack -- Center Post and Assembly |
From "Wood Works"
episode WWK-304 |
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Joinery-Free Construction Once all four of the bent-laminate legs have been made, and shaped on either end with decorative accent curves, the next phase of the project is to join the four legs together. To assemble this particular rack, no joinery is needed. This is because the four long legs are glued using a long walnut center post (figure A). Because the legs are glued to the post long-grain to long-grain, the glue alone is as strong enough bond -- eliminating the need for joinery. The first steps involve cutting and shaping the walnut center-post.
Materials: Walnut stock for post
Table saw
Band-saw
Pattern-maker's rasp
Sandpaper and sanding block
Carpenter's square with straight edge
Carpenter's pencil
Woodworker's glue
Clamps
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.
Making the Center Post
- The center post is made from solid walnut stock that has been milled down to a final dimension of 1-1/2 inches square -- the same width as the finished legs.
- The length of the post is a design decision. The length of the piece is determined by how much of the center post you wish to see extending beyond the curved portions. For our demonstration, the post was cut to a length so that it would end at the same points where the curves on the shorter legs begin. After determining and measuring the distance you desire, cut the center-post stock to length on the table saw.
- With the center-post stock cut to length, the ends are rounded off so that they will blend visually with the established curves. Using the small curved template (used in the prior section for shaping the feet and tops of the legs), trace a curve onto two adjacent sides of the post stock (figure B).
- The marks serve as a guide for making cuts to create a dome shape on the top of the post. Using the band saw, rough-cut the dome by slowly "nibbling" away each corner, being careful not to cut off layout marks on the adjacent side until the dome begins to take shape (figure C).
- Continue shaping the dome using a pattern-maker's rasp (figure D) and file.
- Woodworking Tip: Files and rasps are one of the most underutilized tools in the woodworker's toolbox, since the temptation to use power sanders or other power tools to shape wood is so great. Files and rasps are much better suited to fine detail work, and they allow greater control for fine-tuning a shape. The pattern-maker's rasp, with staggered tooth pattern, cuts more aggressively. The file has smaller teeth, in even rows, and makes a much finer cut.
- Finish off the shaping process using fine-grit sandpaper and a sanding block to fine tune the dome shape (figure E).
Assembly
- To prepare for glue-up, place the short legs back onto the original template and make a reference mark (figure F) to ensure proper alignment of all components during glue-up.
- To begin glue-up, glue the short legs to the center post using yellow woodworker's glue. Because the long-grain of the post is being glued to the long-grain of the legs, the glue itself is sufficient to make a bond strong enough to bond them without using joinery.
- Once the elements are positioned properly, clamp the partial assembly together (figure G) and let it dry for a few hours.
- Next, remove the clamps and attach the first long leg with glue.
- Flip the rack, and place the long leg into a spacer taped to the assembly table.
- With the assembly held in place by the spacers, glue on the final leg (figure H), making certain it's aligned properly with the center line.
- Clamp the assembly securely (figure I) until th glue has dried.
In the segment that follows, the finishing touches are added to complete the coat rack.
Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
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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