| Table-Top Clock -- Clock-Face |
From "Wood Works"
episode WWK-307 |
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Clock Face With the, stock cut for the wedge-shaped face pieces of the clock face, work can begin assembling the alternating wedges of quilted-maple and wengae to form the face.
Materials: Wedge-shaped veneers
Band saw
Block plane
Hand scraper
Yellow wood-glue
Clamps
Bricks for weight
320-grit andpaper
Carpenter's pencil
Carpenter's tape
MDF or wood cawls
Wax paper
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.
Steps:
- Lay out the wedge-shaped pieces of the face to ensure a good fit (figure A ).
- The face is glued up in halves. The elements of one half are glued up and allowed to dry, then the process is repeated for the second half.
- Before starting glue-up, clamp a piece of straight wood to the table to act as a fence (figure B).
- Apply glue to one edge of the first slice, then to both edges of the second slice (figure C).
- Join the pieces, and apply woodworker's tape to hold the two slices tightly together (figure D).
- Repeating the process, work your way around the first half of the face (figure E) to form one half of the circle.
- Once the wedges of the half-circle are glued together, add a layer of wax paper (figure F), a cawl, and a few bricks (figure G) to keep the wedges flat as they dry. The wax paper serves to prevent the glue from sticking to the cawl.
- Repeat the steps to create the second half of the circle.
- After both sides have dried, use a sanding block to sand the edges of the two half-faces flat (figure H) before gluing them together.
- Apply glue to the sanded edges, and join the two halves together (figure I ).
- Add tape to pull the two halves tightly together (figure J).
- As before, use bricks to hold the two sides flat as the glue dries (figure K).
- For the final step in creating the clock face, the glued veneers are glued onto a 1/2-inch wood substrate for support. The substrate is made from apple plywood cut into a 10-1/4 inch square. The back of the substrate will be covered cherry veneer.
- Before cutting the clock-face veneer to size, make diagonal layout marks on the cut substrate, and position the substrate carefully on the veneers making certain to properly align the hour dividers.
- With the substrate positioned precisely, make layout marks for cutting using the substrate as a guide (figure L).
- Using the marks as a guide, cut the veneer face using the band saw (figure M). Make the cuts about 1/16-inch oversized.
- Apply yellow glue evenly to the substrate using a roller.
- Apply glue to the cherry veneer in the same way (figure N), then place the cherry veneer onto the substrate.
- Apply glue evenly onto the veneer onto the clock face (figure O), and place it onto the substrate.
- Once the pieces are stacked together, apply blue tape to the edges to prevent the pieces from slipping (figure P).
- Place the glued-up clock face between cawls of MDF to even out the pressure, and place the whole assembly into the vacuum press.
- The vacuum press (figure Q) creates more than 1500 pounds of pressure per square foot. In about two hours, the clock face will be securely bonded to the substrate.
- Once the clock face is dry, a sharp scraper is used to remove the excess glue and clean up the surface (figure R).
- Sand the face with 320-grit sandpaper to create a smooth finish.
- Using a block plane, remove the excess glue from once side of the glued assembly to create a straight edge to use as a reference when trimming the face on the table saw.
- At the table saw, align the freshly planed edge with the cross-cut sled and trim-cut the face to its final dimension of 9-3/4-inches square (figure S).
In the segment that follows, the case for the clock is created from solid cherry.
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
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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