DIY Network

Cutting Windows out of End Pieces Windows for the magazine rack are created out of the end pieces. From "Freeform Furniture" episode DFFF-111

Host Amy Devers cuts the windows out of the end pieces, puts a 45-degree bevel on the edges and then sands the beveled edges and finished them with a wipe-on polyurethane.

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Host Amy Devers creates the windows for the magazine rack.

Materials:

Pre-finished colored plywood
Cut list
Tape measure
Safety glasses
Stop block
Clamps
Wax pencil
Fence with 2 slots--(1" apart and small piece of stainless steel bar stock inserted in one)
Dado blades
Ruler
Pencil
Template for cutting window
Drill bit as large as jigsaw blade
Double stick tape
Flush trimming bit
45-degree router bit
Blue tape
Lint free cloth
Wipe-on polyurethane
Sharpie
Stainless steel bar stock
Abrasive cut off wheel
Welding jacket
Earplugs
Face shield
Pre-fabricated feet
Countersink bit
Screws

Tools:

Table Saw
Cross-cut sled
Drill
Jigsaw
Router
220-grit hand sander
Disc sander
Random orbital sander
Combination square
Screw gun
Awl

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Cutting Windows Out of End Pieces

1. Make a template. Before you begin cutting the windows, mark for the cut using the template. Place the template on top of the plywood and trace out the hole (figure A).

2. Do the same thing on the other end piece.

   Note: Make sure the template edges are lined up exactly with the plywood so that the holes will be in the same position on both pieces.

3. Before you rough cut the windows, drill a starter hole for the jigsaw blade (figure B) because it is not made to plunge through wood. Choose a drill bit that makes a large enough hole to accommodate the blade.

4. Clamp the panel to the router table and using a jigsaw rough cut just to the inside of the white line (figure C).

   Note: You need to get as close to the line as possible without making it disappear. A jigsaw is best for this type of job because it is good for curves and interior cutouts.

5. Clean the rough holes in the ends with a router and a flush trimming bit (figure D). (A flush trimming bit is basically a straight router bit with a bearing on the end.)

6. Use double-stick tape to attach the template to the window. Turn on the router and run it along the template to clean up all the excess material.

7. Use a bit to put a bevel on the edges (figure E). (It is almost the same concept as the flush trimming bit but on 45-degrees). Put the angle on the exposed edges. Do not put one where the sides meet the bottom or on the inside of the dado joints.

8. Mark the edges that won't be beveled with blue tape. Bevel the inside of the window, flip the piece over and bevel the other side.

9. Do the edges. Repeat this process on all of the other pieces.

10. Once all of the pieces have a 45-degree bevel, sand the edges of the plywood with a 220-grit hand sander.

11. Apply two coats of a wipe-on polyurethane finish to the exposed plywood edges using a lint-free cloth (figure F).

12. Repeat this process on all of the other pieces. Once you have finished applying the finish, let it dry for four hours.

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