| Blanket Rack -- Template and Cherry Stock |
From "Wood Works"
episode WWK-306 |
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In this episode of DIY Wood Works, host David Marks builds a blanket rack of solid cherry with inlays of maple and exotic Zirocote wood. The design for the piece is a study in symmetry, but the focal point is the handmade signature inlay. The clean lines of the rack are enhanced by the warm tones of the cherry wood. The sturdy legs are joined at the top by a graceful, curved crest-rail highlighted by the multicolor inlay. Materials: Cherry stock
MDF for template
Table saw
Jig saw
Table router
Drill press; Forstner bit
Chisel
Rasp
Straight-edge
Carpenter's pencil
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, power-tools, saws, drills, routers, etc. Template and Cherry Stock - The project begins with a design diagram for creating the MDF template. A full-scale drawing of the side-piece is made from 1/8-inch MDF. A center-line is marked as a guide, and a flexible strip is used to help determine the proper curve (figure A).
- Once the full-scale design is established, the full-scale drawing is cut out and used to make the MDF template. To make the leg symmetrical, trace the thin, curved template onto a sheet of 1/2-inch MDF, making sure to match up the center lines ( figure B). The leg is flipped over, with the center lined up again, and the leg is re-traced on the 1/2-inch MDF.
- The result is a tracing with an outside and inside line (figure C). Whichever curve looks best aesthetically becomes the reference for cutting. Once cut out, the 1/2-inch template is used as a guide to make both legs of the rack.
- Next, the layout marks are made for the joinery, encompassing the three stretchers and the top crest-rail. The mortises are to be centered in the legs, and the rails and stretchers are to be parallel to the floor. The mortises for the two bottom stretchers are set in equal distance from the edges of the curved leg (figure D). All mortises for the top and bottom stretchers are the same size: 7/8-inch long by 3/8-inch wide.
- For the crest-rail, a mortise is cut 2 inches long by 3/8-inch wide. It's positioned 1-1/4 inches down from the top of the leg (figure E).
- With all the mortises laid out, cut out the template from the MDF using a jig saw (figure F), making certain to cut close to the layout marks to minimize finishing time.
- Use a pattern-maker's rasp to smooth the edges.
- Finish the job with a sanding strip (figure G).
Tip: A flexible sanding strip can be made by attaching some 120-grit sandpaper to a strip of 1/8-inch maple (figure H). This flexible strip can be used to smooth the contours of the curved template. - At the drill press, use a Forstner bit to drill out the mortises for the stretchers (figure I). Drill the mortises all the way through on the template so that they can be used to mark the layout on the actual legs.
- Square up the edges of the mortises using a sharp chisel (figure J).
- With the template complete, work can begin on building the blanket rack. Use solid cherry that's been milled 7/8-inch thick. To get the necessary width for making the legs, edge-glue two 8-inch-wide boards together.
- Use a scraper to clean up the surface and remove any excess glue from the glued cherry (figure K).
- Using a straight-edge, draw a center line where the two boards were joined. That line will be used as a reference for the template.
- Using the table saw and cross-cut sled, trim one end of the cherry plank.
- Trace the MDF master-template onto the stock and trace the leg design, making certain to line up the feet of the template with the straight edge just cut on the table saw (figure L). Also, transfer the mortise marks for the stretchers and crest-rail onto the stock.
- Use a jig saw to cut out the leg shapes from the cherry stock (figure M), making certain to cut close to the traced lines. This will minimize the amount of routing that will be needed later.
Note: Be sure to save the fall-off when you cut the cherry stock. It will be used later. - With the legs cut out, flush trim the edges at the table router table (figure N).
- Tip: To minimize chip-out on the curved pieces when cutting across the grain, it's advisable to use a climb-cut on the router. Climb cutting consists of moving the stock in the same direction of the rotating bit.
- Once the legs pieces are cut, clean up the inside edges of the legs using a pattern-maker's rasp (figure O).
- Use a chisel to create a fine point at the apex of the wishbone.
- At the drill press, use a Forstner bit to cut the mortises for the stretchers and crest rail (figure P). Remove the bulk of the stock with the drill, then square up the mortises using a sharp chisel.
In the segment that follows, the curved crest-rail and joinery are made.
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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