| Contemporary Wine Caddy -- Joinery |
From "Wood Works"
episode WWK-412 |
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With the case pieces cut and shaped, work can begin on the joinery that will hold them together. With that done, the glass-hangers can be made and suspended from the underside of the top-shelf Materials: Table saw
Biscuit joiner
Plunge router
Table router
Carpenter's tape
Yellow 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, power-tools, saws, drills, routers, etc. Joinery - Biscuits are used to join all of the parts. Begin by cutting the biscuits in the bottom piece, centering the biscuits in the thickness of the board and spacing them evenly. Remember to leave room for the rabbet that will hold the back panel.
- With the biscuit joiner set to cut #20-sized biscuits, cut three slots along the end-grain of the bottom panel (figure A). Cut slots on both ends of the board.
- As seen in the prototype, the assembly calls for a bottom that is stepped up and back, creating a 5/16-inch reveal (figure B).
- For the layout, uses the slots that were just cut as a guide. Line up the parts so that they are flush along the back edge, then pencil in layout lines. Then adjust the fence on the cutter, increasing the height, to create the offset along the edge.
- Once the fence setting is adjusted, cut three #20 biscuit slots on the two side panels (figure C). Conduct a dry-fit to ensure that the pieces fit together properly.
- Next, cut a rabbet for the back edge of the side and bottom pieces to accommodate the back panel. Using a plunge router, cut a through-rabbit that's 3/8-inch deep by 3/4-inch wide along the edge of the bottom panel. Since the rabbets need to stop short of the bottom edge, on the side panels clamp (figure D) a stop-block in place before cutting the rabbets. For safety, make the cuts in multiple passes.
- The next step is to lay out and cut the biscuits that will attach the bottle brackets to the sides of the piece. To figure out the placement, adjust the distance between the brackets until the bottles can rest securely (figure E). To allow for room and easy access between the upper and lower brackets, a distance of 3-3/4-inches is left between them.
- Use the biscuit joiner (figure F) to cut slots in the center of each end in the bracket (figure G).
- To cut the connecting slots on the case, reference the fence of biscuit cutter against a stick clamped to the stock. The stick serves as an auxiliary fence, and prevents the biscuit joiner from moving.
- The 3/4-inch stock for the top shelf is 7 inches wide and 15-1/2 inches long. The shelf should be positioned so that it sits 3 inches down from the upper edge of the case (figure H), allowing room for the decorative trim that will be added later.
- Cut #20 biscuit slots along both ends of the top shelf (figure I).
- Again using a clamped stick as an auxiliary fence, cut matching slots on the sides of the case referencing the fence against the clamped stick (figure J).
The Glass Hangers The top is designed to hold 8 glasses, and the hangers made from 1/4-inch stock. The goal is to keep the grain running in the same direction to provide strength for supporting the glasses, and to allow for wood movement. The hangers are made by making T's -- cutting dados in the wider stock, then gluing narrow pieces in the dado to form the "T." To join the hangers to the tip, dados are cut on the bottom of the shelves (figure K). - At the router table, use a 1/4-inch bit to make 1/8-inch deep dados in the center of the bottom hanger stock.
- Adjust the fence and use the same bit to cut 1/4-inch dados in the bottom of the top shelf. Space the dados evenly, and about 3-1/4 inches apart. To prevent the dados from showing through the front, stop each dado-cut about 5/8-inch from the end of the stock (figure L).
- Used a sharp chisel to square up the dados, then ease each of the dados with 220-grit sandpaper.
- With the dados cut, the pieces can be glued together to make the T-shaped hangers (figure M). Brush yellow glue into the dados, position the pieces together and clamp the assemblies to the workbench to dry.
- We glued up a total of five T's. However, the design only requires three T's and two L-shaped hangers (figure N).
- Once the glue has dried, one side can be cut away on two of the T's to create the L-shaped hangers for the ends. At the table-saw, set the fence and trim off one side of the "T" using a 40-tooth carbide blade (figure O).
- Once all the pieces have been cut, ease the exposed edges of the caddy using a 1/8-inch round-over bit at the router table.
In the segment that follows, the wine caddy is assembled and glued up.
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
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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