DIY Network

Open Display-Case -- Shaping Curved Edges From "Wood Works" episode WWK-309

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I Figure J Figure K

With the case stock cut and mortises created for the joinery, tenons are milled from walnut stock. The tenons are rounded on the ends, using a 1/4-inch radius bit at the router table, to match the fit of the mortises (figure A). They are then cut to length at 1-1/2 inches.

With the tenons made, dry-fit the elements of the case to ensure a good fit. Place the tenons in the mortises of the base and add the side pieces (figure B).

With the sides fitted to the base, attach the top (figure C) using mortises.

Shaping the Curved Edges

With the proper fit of the elements assured, work can begin on hand-shaping the curved edges of the top and bottom of the case. If the top and bottom pieces had straight edges, the shaped profile could be created by making a cove cut at the table saw. However, since the edges themselves are curved, a die-grinder is used. A die-grinder is a sculpting tool that provides power and speed for carving and shaping wood.

Materials: Die-grinder and ball-mills
Micro-plane
Rasp
Gooseneck scraper
Sandpaper
Straight-edge
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, power-tools, saws, drills, routers, etc.

Safety Alert: When working with the high-speed die-grinder, be sure to wear gloves and exercise the highest level of caution.

• Carve between the channel at the bottom of the slab and the line routed near the top using the die-grinder (figure D).

• Rough out the bulk of the curve with a 5-flute, high-speed steel ball-mill (figure E).

  Note: The 5-flute steel ball-mill is a specialty accessory that may need to be special-ordered.

• To refine the curve, replace the 5-flute ball-mill with a carbide ball-mill that has a smaller tooth-pattern (figure F). The carbide ball-mill is commonly available at tool-supply stores.

• To finish the job, hand tools will be used. Begin with a micro-plane, a shaping tool that resembles a cheese-grater (figure G). The teeth of the micro-plane are razor-sharp, and won't clog with wood.

• Next, use a pattern-maker's rasp with a staggered tooth-pattern (figure H) to continue shaping the curve.

• Use a goose-neck scraper to smooth out and refine the final curve.

• To ensure that the curve is uniform all the way around, create a small curved template of MDF. Set the template into the curve (figure I), and move it along the edge to see if any further shaping is needed.

• For the final touch, use 220-grit sandpaper taped to a wooden dowel to create a silky-smooth surface within the curve (figure J).

• With the top and bottom complete, and the shaping done, dry-fit the pieces once again (figure K) and take final measurements back panel and the layout for the rabbet that will hold it in place.

In the segment that follows, the back-panel is made using a vacuum press and maple veneers.

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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

Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com