| Game Board -- Joinery |
From "Wood Works"
episode WWK-411 |
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With the checkered center and the frame-pieces made, can begin on the spline joinery to join the frame to the board. Materials: Table router; miter gauge
Band-saw
Disc sander
Hand-held router
Hand scraper
Slow-setting plastic-resin 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, power-tools, saws, drills, routers, etc. Steps:
- At the table router, cut a dado in all four sides of the checkerboard using a 3/16-inch slot cutter set for a dept of 3/8-inch.
- Use the same settings to cut through-dados along the inside length of the frame (figure A) on all four parts.
- Stop-dados are cut along the miters, since there will be some decorative shaping of the frame later. Mark the miter about an inch from the end (figure B) to indicate the end of the stop miter.
- Remember that each miter has a left and right side, so clamp mitered stop-blocks to the fence to ensure accuracy.
- Referencing the show-side of the frame-stock down, cut a stop-dado on the right side of all four pieces (figure C).
- Next, re-set the stop-block on the fence, then cut stop-dados on the left side of all four pieces (figure D).
- The splines for the dados are cut from walnut on the band saw. Cut a piece of walnut stock into strips that are 3/4-inches wide by 23-1/4 inches long and 3/16-inch thick.
- At the drum sander, sand all of the walnut strips to uniform thickness.
- At table saw, cut the strips into four long splines and four short splines.
- Check the fit of the splines before gluing (figure E). Avoid splines that are too tight, as this may cause problems due to expansion of the wood later on. If the splines are too snug, you may need to do a little extra sanding or scraping to finesse the fit.
- To cut the miter on the ends of the four long splines, use the disc sander. Tape the four long splines together, and use a 45-degree jig at the sander to ensure the proper angle (figure F).
- Since the wing-cutter left a curve at the end of the stop-dado on the mitered frame, the ends of the short splines need to be rounded to match the fit of the dados. To do this, trace the rounded shape onto the end of the spline stock using the wing-cutter as a guide (figure G).
- At the disc sander, grind the stack of short splines to match the curve of the layout mark (figure H).
- The challenge of the final glue-up is to getting all of the pieces to line up so that the decorative banding of ebony and satinwood runs seamlessly all around the frame. Begin by placing the checkerboard onto a 1/4-inch caul (figure I) to raise it enough match the height of the 1-inch frame. Check the fit of the pieces to ensure that all pieces come together perfectly.
- Use slow-setting plastic-resin glue to allow ample opportunity to line up the joints during glue-up. Brush glue onto the short splines, then slide them into position in the corresponding dados (figure J).
- Brush glue into the dados and onto the long splines, and slide the long splines into position as well (figure K).
- Bring the pieces of the frame together with the board, and use a band-clamp to pull the joints together (figure L), making any necessary adjustments to the alignment as the clamp is tightened.
- Once the pieces are lined up precisely, secure the assembly with clamps from all directions (figure M), and allow the glue to dry.
In the segment that follows, the edges of the board are given a decorative bead and bevel, and a wood finish is applied. 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
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
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