| Mahogany Wine Rack -- Assembly |
From "Wood Works"
episode WWK-203 |
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Case Completion and Final Assembly With the honeycomb structure complete, and the outer case-pieces cut, final assembly of the wine rack can begin. Materials: Biscuit joiner; zero biscuits
Table router; radius bit
Hand router
Table saw
Carpenter's square
Chisel
Hand-plane
Yellow wood-glue
Carpenter's pencil
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, saws, drills, routers, etc. Steps:
- Using a biscuit joiner set to cut slots for zero-biscuits, cut biscuit slots in the top, bottom and side pieces to join the corners of the case together.
- With the slots cut, dry-fit the end pieces to the tip and bottom to check for proper fit (figure A).
- With the structure dry-fit together, lay out marks that will be used for the biscuit joinery that will be used for attaching the ends of the honeycomb to the inside of the case. Start by scribing a center line on the edges of the honeycomb (figure B).
- Transfer those lines to the matching sections of the case (figure C).
- Extend those center lines onto the outside edges of the honeycomb (figure D) to lay out the biscuits.
- Use the jig that was used in the preceding segment (laying out new marks on the backside of the jig) to determine spacing for the biscuit slots. To mark for the slots for the biscuits on the outside of the honeycomb -- that will attach to the case -- a spacer is used on the jig to compensate for the step-down between the case and the long diagonals (figure E).
- To cut the biscuit slots on the outside of the case, set the fence on the biscuit joiner at 45 degrees (figure F).
- Next, set the fence to 90 degrees to cut the corresponding slots in the top, bottom and sides of the case (figure G). This time, the spacer is removed from the jig (figure H) so that the slots on the case will match up with the ones on the honeycomb.
- With the joinery made, the case can be glued to the honeycomb. Start by gluing the top and bottom pieces to the honeycomb (figure I), clamping securely as you proceed.
- Finally, add the sides of the case and clamp to the corners of the honeycomb (figure J).
- Before cutting the mahogany plywood back-panel for the wine rack, a rabbet is cut in the back of the case using a hand-router (figure K). To help prevent chip-out, two passes are made for each cut.
- Square the corners of the rabbet using a sharp chisel (figure L).
- Using a table saw, cut the back panel to final dimensions out of 1/2-inch mahogany plywood. Once it is cut, check the fit of the panel in the rabbet (figure M). A few passes with a hand-plane may be needed to get a perfect fit.
In the segment that follows, the panel is installed and a wood finish is applied to the wine rack. Sponsored Resource
> 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
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
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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