| Walnut Display Stand -- Shelf Supports |
From "Wood Works"
episode WWK-209 |
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The Shelf Supports With the, leg pieces cut and assembled, work can begin on the walnut frames that will hold the glass shelves. Each frame (figure A) is 21 inches square and has 45-degree miters at the corners. The miter joints are reinforced at each corner by use of a spline joint. Once the piece is assembled, the spline joints will be concealed by the legs.
Materials: Black-walnut stock
MDF for cradle
Table router; rabbet-cutting bit; flush-bearing bit
Table saw
Miter jig
Band saw
Band clamp
Spring clamps
Yellow wood-glue
Clamps
Carpenter's pencil
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:
- Since the frame stock was cut earlier, start this phase of the project by batch-cutting a rabbet in each piece of the stock at the table router (figure B).
- Cut each rabbet 3/8-inch wide by 1/4-inch deep (figure C) with two passes on the table saw using a rabbet-cutting bit. By making the cut in two passes, chip-out is minimized.
- With the rabbets cut in all of the shelf-stock pieces, move on to cutting the miters using the table saw and a miter-jig (figure D).
- Position the stock with the rabbet facing the fence, and cut one miter on the left side of the jig (figure E). Then switch the stock to the other side of the jig to cut the miter at the other end of the stock. Batch-cut all of the pieces in this way, using a stop-block to ensure that all pieces are cut to exactly the same length.
- Tip: There will be a total of eight cuts (i.e., two cuts on each side of the four sides) on every frame. This comes to a total of 40 miter cuts, so make sure your saw blade is sharp before you begin.
- A miter is not a particularly strong joint, so each corner will be reinforced using a triangular spline. Before cutting slots for the splines, however, the shelf-frames must first be glued together. With the frames glued together first, the miters will have a strong, tight fit. The slots can then all be cut consistently and accurately in each corner. Glue each of the frames together using yellow glue and a band-clamp to provide bonding pressure (figure F).
- To make the precise cuts in the glued frames for the splines, a cradle is made from MDF that will hold the frame in position as the slots are cut on the table saw (figure G). Use spring clips to clamp the frame securely into the cradle.
- Important: For cutting the corner slots, use a saw blade that has a square-tooth configuration (figure H). In that way, the corner slots won't have any jagged edges.
- With the frame clamped into position (figure I), the blade is set to cut a slot about 1-1/4 inches into each corner (figure J).
- With all of the slots cut in the frames, you can begin making the splines. Each spline (figure K) is cut from black walnut stock that's been milled to about 1/8-inch thick.
- Cut the splines to size using the band saw (figure L).
- Once they've been cut to dimension, brush glue onto the splines and slide them into the slots (figure M).
- Clamp the assembly securely, using corner blocks, as the glue dries (figure N).
- Once the glue has dried, trim off the excess spline material from each corner using the table router and a flush-bearing bit (figure O).
In the segment that follows, the top and bottom accents are fashioned out of wengae, and the stand is assembled.
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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
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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