| European Dish Rack -- Side Panels and Fretwork |
From "Wood Works"
episode WWK-410 |
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Side Panels and Fretwork With the frame, front assembly and support rail complete, work can now begin on the side panels that feature decorative fretwork. Materials: Table saw
Drum sander
Table router; flush-bearing bit
Scroll saw
Flexible-shaft grinding tool
Flap sander
Hand scraper
220-grit sandpaper
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. Steps: - Cut the two oak side-panels to proper length (11-3/4 inches) using the table saw with cross-cut sled.
- The stock for the side panels should be thick enough to be sturdy, but not so thick as to make fretwork difficult. Use the drum sander to ensure that both panels are exactly 1/4-inch thick (figure A).
- The panels will be held in place in dados cut along the inside edge of the frames. At the router table, with the stop-block positioned along the fence, cut stop-dados in each of the posts (figure B). The dados should be cut 1/4-inch deep, and should run between the two mortises (figure C).
- Remove the stop-block and cut through-dados in the side rails (figure D).
- Now work can begin on the decorative fretwork. Much of the work in this phase of the project is done using a scroll saw. Begin by creating a design on paper. Once you have a design you like, make a few copies. Glue the design onto the panels (figure E) using a light coat of glue.
- Drill small piercing holes through each of the larger sections of the design (figure F). Place the panel on scrap MDF to prevent chip-out as you drill each section (figure G).
- Thread the scroll-saw blade through one of the holes and clamp it securely (figure H).
- Now you can begin cutting out the design on the scroll-saw (figure I).
Tip: Cutting with a scroll saw is not difficult, but it does take some practice to get the feel of the technique. Apply steady pressure as you cut. As you cut around bends and corners, ease up on the pushing pressure to prevent the blade from lunging. - Meticulously work your way around the design until each section of the pattern is completely cut out (figure J).
- Use a hand-scraper to remove the leftover paper pattern (figure K).
- To add a three-dimensional look, use a flexible-shaft grinder to carve shallow channels to connect the individual sections (figure L).
- Use a 220-grit flap-sander (figure M) to clean and smooth the edges of the design (figure N). The flap-sander is an ideal tool for finish-sanding irregular and contoured surfaces.
- Finally, add glue to the mortises and tenons in the rails to glue the side panels in place.
- Clamp the assembly securely (figure O) to allow the glue to dry.
In the segment that follows, the dish rack is assembled and a wood finish is applied.
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
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
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