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  • Cutting the Parts
    		•
    The magazine-rack project begins by cutting the parts and dado grooves.
    From "Freeform Furniture"
    episode DFFF-111


    (Continued from page 1)

    PHOTO

    Figure D
    PHOTO

    Figure E
    4. Measure out from the blade and attach a stop block at one end (figure D).

    Note: A stop block is a cutting guide that is placed the same length from the blade that you want the pieces to be cut. It allows you to manage your cuts and maintain your measurements without having to stop and measure each time.

    5. Using the crosscut sled, cut the side pieces to length. Reposition the stop block to match the measurements for the bottom piece and then cut the pieces (figure E).

    6. Repeat the process for the ledger strips and caps.

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    PHOTO

    Figure F
    PHOTO

    Figure G
    PHOTO

    Figure H
    PHOTO

    Figure I
    PHOTO

    Figure J
    7. Still using the crosscut sled, cut all the grooves in the ledger strips to hold the stainless steel bars. You want each of the slats to be 1" apart on the ledger strip (figure F) but instead of measuring for all of that make a jig.

    8. To make the jig, mark where the first two slats are going to go. The jig supports the work piece and guides the cutting tool. You can also use it as a cutting guide.

    9. Cut the first groove.

  • FYI: The material that is eaten away by the saw blade is called the kerf (figure G).

    10. The next step in making the jig is to use the fence--line up the second mark with the saw blade. When it is in position, clamp it in place.

    11. To use the jig, carefully slide the ledger strip through the blade. Then move the new groove you just made onto the little piece of metal attached to the fence. The next time you cut a groove, it will be 1" from the previous groove.

    12. Continue this all the way down the strip (figure H), which evenly spaces out the grooves and then do the same thing with the other strip.

    13. Now that all the parts are cut, it is time to start cutting the joints. All of the sides are going together with dado joints.

    Note: A dado groove (figure I) is cut by using a set of dado blades on the table saw. A dado blade is a type of saw blade designed to create a wide groove in the material. Dado blades are a good way to get perfect fits with just about any type of joinery. Dado cuts are used in many types of wood construction. Cutting dados properly requires precision measurements.

    14. Dado blades consist of two circular saw blades that sandwich chippers in between them. The number of chippers you use determines the width of your cut. Typically, you want your groove to be about the same size as the wood you are using to insure a tight fit. Make a test cut to make sure your joints are going to fit together the way you like them.

    15. To cut the grooves on the side pieces, set the height of the dado blades. Also set the fence, which is a parallel cutting guide. Leave enough space on the ends to create the bevel. I need two grooves on each side piece, so I push it through, flip it over, and feed it through again (figure J). I do the same thing with the other side piece.


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    RESOURCES :

    Delta Woodworking Power Tools
    Website: www.deltawoodworking.com

    Festool
    Website: www.festoolusa.com

    Gladiator Garageworks by Whirlpool
    Website: www.gladiatorgw.com

    Stanley Tools Product Group
    Website: www.stanleytools.com

    Lie-Nielsen Toolworks, Inc.
    Website: www.lie-nielsen.com

    WMH Tool Group
    Website: www.wmhtoolgroup.com

    Power Tools (Porter Cable)
    Porter Cable Power Tools
    Website: www.portercable.com

    Hand Tools
    Garrett Wade Co., Inc.
    Website: www.garrettwade.com

    The Peck Tool Company
    Website: www.pecktool.com

    Biesemeyer
    Website: www.biesemeyer.com

    Saw Blades
    Forrest Manufacturing Company
    Website: www.vacupress.com

    Jogensen Adjustable Clamp Company
    Website: www.adjustableclamp.com

    Adhesives, Abrasives and Safety Equipment
    The 3M Company
    Website: www.3m.com

    Klein Tools
    Website: www.kleintools.com

    Ulmia GmbH
    Website: www.ulmia.de

    Woodcraft
    Website: www.woodcraft.com

    Shop Equipment
    Eagle Manufacturing Company
    Website: www.eagle-mfg.com

  • ALSO IN THIS EPISODE:
  		• Cutting the Parts
  		• Cutting Windows out of End Pieces
  		• Making Stainless Steel Slats
  		• Assembling the Magazine Rack
  		• Dimension Information and Different Types of Metal Finishes
    		•