| Cherry Corner-Shelf -- Curved Shelves and Banding |
From "Wood Works"
episode WWK-312 |
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Curved Shelves and Banding With the, side panels made, the shelf dados cut, and the wengae stock cut for the edge-banding, the next phases in the project are the creation of the quarter-round shelves and the application of bent wengae caps to the shelves' edges. Materials: Cherry stock
Wengae stock
MDF for template and gluing jig
Band saw
Table router
Pattern-maker's rasp
Universal razor saw
Hand-scraper
Sanding strip
Yellow wood-glue
Clamps
Double-stick tape
Straight-edge
Carpenter's pencil
Carpenter's tape
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: - Each piece of shelf stock measures 15 inches square. These pieces will be cut into the curved shelves, and capped with wengae for an eye-pleasing contrast. To cut the curves, a curved template is made first out of MDF.
- With a 15-inch square of MDF, measure out inch and draw lines parallel to two adjacent edges (figure A). At the intersection of the two lines, use a large compass with a 14-1/2 inch radius, and draw out an arc from line to line.
- Using the curved line as a reference, cut out the arc on the band saw (figure B).
- Smooth the edges of the curved template with a pattern-maker's rasp (figure C) followed by a flexible sanding strip. This template is made to create the shelves.
- Place the curved template on the shelf stock, and trace the line of the curve onto the plywood (figure D).
- With the curve transferred to all of the stock pieces, cut out the shape -- slightly oversized -- at the band saw.
- Double-stick tape the MDF template to the shelf-stock, and flush-trim the edges of the plywood stock at the router table using a flush-trim bit (figure E). Repeat this process for all five shelves.
- With the shelves cut, the next phase is to band their edges with the strips of wengae. To secure the banding to the shelves while they bond, a curved gluing jig is made from MDF (figure F). Add a layer of cork to the face of the concave caul to distribute the bonding pressure. Add plastic packing tape on the curved face to ensure that the wengae doesn't stick to the template. Use 1/16-inch shims to keep the wengae centered on the edge of the shelf.
- Apply glue to the edge of the shelf (figure G) and to one face of the wengae. In both cases, make sure not to put any glue within 1 inch of the ends (figure H). This is in preparation of the gap that will need to be left in the wengae banding where the legs join the sides and shelves. By not gluing that portion on both sides, it will be easier to remove the excess portion of wengae banding.
- The gluing jig holds the wengae strip firmly against the edge of the shelf to form a tight, even bond as the glue dries. The jig also provides straight edges for the clamps to hold onto so that they will provide uniform pressure (figure I).
- After the glue has dried, and the shelves have been removed from the jig, use a universal razor saw to carefully cut one inch of the wengae banding off either end -- leaving the plywood corners exposed (figure J).
- Use a hand-scraper to flush the wengae banding smooth with the surface of the shelf (figure K).
In the segment that follows, the legs are made and the corner shelf is assembled. 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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