| Blanket Rack -- Curved Crest-Rail and Joinery |
From "Wood Works"
episode WWK-306 |
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With the curved legs made, work can begin on the stretchers and crest-rail, and the joinery can be completed for the structure. Materials: Cherry stock (fall-off from the leg pieces)
MDF for template
Table saw
Band saw
Table router
Hand-saw
Carpenter's pencil
Double-stick 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, power-tools, saws, drills, routers, etc. Crest Rail - The fall-off from cutting the curved leg pieces (figure A) was retained from the last phase of the project. This stock is used to cut out the crest-rail and stretchers.
- With the stock cut for the rail and stretchers, work can begin on the joinery for connecting the pieces. It's a good idea to cut all the joinery at once, including the tenons on the crest-rail. The crest-rail is a curved piece. Because it's more difficult to cut a tenon on a curve, the tenons are cut first, while the stock is still square.
- At the table saw, begin creating the tenons by setting the blade at 1/4-inch and score two long cheeks (figure B) on each end of the crest-rail stock.
- On the stretcher stock, use the same setting to score all the way around (figure C).
- At the band saw, with the fence set 3/16-inch from the blade, cut off the shoulders on the narrow ends of the stretchers, leaving an exposed tenon (figure D).
- Next, maintaining the same settings, cut off the two cheeks on each end of the crest-rail (figure E).
- With the tenons all cut, work can begin shaping the crest-rail. As part of the design, seen in the prototype in (figure F), the top of the curve is to be at the same height as the top of the legs.
- The lines of the curve are laid out using a template created using MDF (figure G). The template is made extra long to help protect the tenons as the shape is cut and routed on the curved rail.
- Double-stick tape the template onto the stock. At the band saw, using the template as a guide, cut out the curve for the crest-rail (figure H). Make the cut about 1/16-inch oversized.
- With the template still attached, trim the edges flush at the router table using a 1/2-inch spiral bit.
- Use a Japanese hand-saw to cut away the side-shoulders on the crest-rail, completing the tenons (figure I).
In the segment that follows, the decorative inlay is made before gluing up the assembly.
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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
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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