DIY Network

Gilded Three-Panel Screen: Final Assembly and Finishing Touches From "Wood Works" episode WWK-610

The finished three-panel screen. The rich color of the mahogany frame -- darkened with the potassium dichromate and finished with tung oil -- surrounds and highlights the striking copper-gilded panels and textured patina.

The final steps in the creation of the three-panel screen include the assembly of the three framed panels to form the completed piece, and the application of finish to the frame and panels.

Materials:

Paint sprayer
Spray-on vinyl sealer
Spray-on lacquer
320-grit sandpaper
Drill press
Cordless drill
Plunge router
Sharp chisel
Hinges
Potassium dichromate
Tung-oil finish
Paint brushes
Rags

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

Safety Alert: Always wear protective gloves, and ensure adequate ventilation, when working with wood stains, solvents and other toxic solutions. When working with some sprays and chemicals, a respirator mask may be required.

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Figure A

Protective Finish, Final Assembly and Finishing Touches

• Once the panels have been gilded and the patina process has been completed, seal the panels with a lacquer finish. The first step is to spray on a vinyl sealer. This clear finish will seal in the color and keep the copper from oxidizing further. This protective finish is moisture-resistant, and serves as a primer for the lacquer top-coats. One or two coats should be sufficient. As you spray, hold the paint sprayer 8 to 12 inches away from the surface, and use steady, even strokes (figure A), maintaining the same motion and angle as you spray. Allow the sealer plenty of time to dry between coats.

• Next, to get a richer, professional-looking finish, apply 6 to 8 spray coats of lacquer. After building up a few coats, and allowing them to dry, sand the surface with 320-grit sandpaper between coats.

• Finish up with a single coat of satin lacquer.
  

  Figure B

  
  
  

• While the lacquer is drying on the panels, the hinges can be installed on the frames. The hinges we used (figure B) had an antique copper finish and were designed specifically for use with folding screens. They are made to pivot on two sides, and are thin enough that they won't interfere with folding the screen flat for easy storage.
  

  
  

• To install the hinges, mortises will need to be cut in the sides. For accuracy, clamp the two frames that will be hinged together side-by-side, and make the layout marks for the mortises.

• Once the marks for mortises have been properly laid out, cut the mortises to the correct depth of 1/8" deep using the plunge router (figure C).

• Clean up the boundaries of the mortises using a sharp chisel (figure D).

  Figure C

  Figure D

  
  

  
  

• Drill pilot holes in the panel-stops at the drill press (figure E).

• Before installing the hinges and panels, apply the wood finish on the frame. We opted for potassium dichromate to darken the mahogany, leaving a deep, red-brown tone. Apply several coats until you achieve the desired tone.

  Safety Alert: Potassium dichromate is toxic. When applying it, wear protective gloves, eye protection, and work in a well-ventilated area.

• After darkening the wood, we applied several coats of tung oil (figure F) to seal in the grain and highlight the color.

  Figure E

  Figure F

  
  

  Figure G

  
  
  

• Once the frame is dry, assemble the panels. Position the gilded panels in the rabbets that were cut into the frame earlier (figure G).

• Set the panel stops in place.
  

  
  

• Secure the panel stops using antiqued brass screws (figures H and I). We used a sheet of cardboard to protect the panel from being scuffed by the drill.

  Figure H

  Figure I

  
  

  
  

RESOURCES :

Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456

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

Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com