DIY Network

Zebra-Wood Corner Display: Stock and Veneers From "Wood Works" episode WWK-703

	This corner display features a step-down profile, curved edges and rounded corners that complement the striking grain-pattern of the wood.
	Contrasting stripes and distinctive color banding are the hallmarks of the appropriately named zebra-wood used for this corner display.

In this episode of DIY Wood Works, host David Marks creates three-shelf corner display from a stunning African hardwood.

Standing four feet high, this corner display is crafted from zebra-wood and reveals a graduated, Asian inspired, step-down design. The two sides are made by edge-gluing boards together to get the width needed for the design dimensions. The three shelves are curved and increase in size from top to bottom. The sides of the display are made from solid wood, while the front, top and bottom faces of the three shelves are veneered to prevent wood movement. The shelves are made by adding zebra-wood veneer onto plywood and banding on the front edge. They are attached to the sides with biscuit joinery.

In this first segment, work gets underway preparing the zebra-wood stock and veneered shelves.

Materials used in this episode:

Zebra-wood stock
Baltic birch plywood stock
Cocobolo stock
MDF for templates
Table saw; cross-cut sled
Jointer
Drum sander
Table router; flush-bearing bit
Plunge router
Biscuit jointer
Jig saw
Spoke shave
Rasp
Clamps
Yellow woodworker's glue
Glue roller
Straight-edge
Measuring tape
Compass
Carpenter's pencil
Blue carpenter's tape
Safety glasses or goggles

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

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Figure A

Zebra-Wood Stock

Zebra-wood is a fine-looking hardwood, but one with a couple of unusual characteristics. For one, woodworkers who use it report that, when it's cut, it has a smell not unlike a "wet dog." For another, it is a wood that's prone to splintering. It requires some care when handling.

As seen on our prototype (figure A), the finished corner table is 48" tall, and each of the two sides is 12" deep.

• To create the layout of the sides, and the curves, David fashioned a template out of MDF (figure B). The shelves are evenly spaced -- 15" from the bottom shelf to the middle shelf, and 15" to the top shelf. The sweeping curves of the sides will provide a sleek profile in the finished piece.
  
  
• Since our zebra-wood stock is narrow, three pieces were edge-glued together (figure C) to achieve the necessary width.

  Figure B

  Figure C

  
  

  
  

• To prep the stock, joint one face and one edge on each board (figure D).
  
  
• Next, run each board through the planer to get the opposite face parallel.

• Then drum-sand the boards to a uniform thickness of 3/4" (figure E).

• At the table saw, cross-cut the boards to length, leaving them slightly oversized. Cutting the boards a little long will allow room for shaping later.

  Figure D

  Figure E

  
  

  
  

• Inspect each blank, and arrange them to match the grain so that the three boards together look like one solid piece of stock. Mark the order of the boards with a cabinet-maker's triangle (figure F).
  
  
• To edge-glue the boards, apply an even amount of yellow glue to the edges of each board, align the triangle and apply uniform pressure with clamps. To ensure that the boards dry flat, it's a good idea to apply uniform pressure using cauls (figure G).

  Figure F

  Figure G

  
  

  
  

While the sides are drying, you can begin work preparing the substrate and veneers for the shelves. Each of the three shelves is a different size. The top is 9" long, while the middle 10-3/8" and the bottom is 12-1/4". Each shelf starts with a veneer about 1/8" thick on both sides of a piece of 1/4" plywood. Each is then banded with another slice of zebra-wood veneer.

• To make the shelf templates, use a large compass, and trace out the arcs onto some 1/2" MDF.
  
  
• At the band saw, cut out each shape close to the marked line (figure H).

• Smooth the curved edges of each using a pattern-maker's rasp followed by a flexible sanding-strip (figure I).

  Figure H

  Figure I

  
  

  
  

• At the band-saw, re-saw a board of zebra-wood to a veneer that's 1/8" strong (figure J).
  
  
• Pass each veneer through the drum sander to bring them all to uniform thickness of 1/8" (figure K.

  Figure J

  Figure K

  
  

  
  

• At the table saw, using the cross-cut sled, cut the veneers for the shelves, leaving them slightly oversized.
  
  
• Pass each edge over the jointer in preparation for edge-gluing (figure L).

• Apply yellow glue to the veneer edges, tape the joint-line together and apply pressure with clamps (figure M).

  Figure L

  Figure M

  
  

  	Figure N
  	Figure O

  
  

• While the glued veneers are drying, you can begin cutting the substrates for the shelves. At the table saw, cut three sheets of 1/4" Baltic birch, leaving them a little larger than the shelf templates (figure N).
  
  
• Wood Works Tip: In order to keep the proper flow of the grain patterns throughout the piece, the zebra-wood veneers should oriented onto the substrate as shown in the photo (figure O). If the veneers were placed square to the edge on each substrate, it wouldn't harmonize with the grain-pattern on the sides. But with the veneers oriented as shown, the grain-pattern flows down the sides and across the shelves. It's attention to details like this that differentiates fine woodworking technique, setting it apart from the mere ordinary.
  

  Figure P

  
  

• To prep the pieces that make the shelves, trace the caul -- that will be used to press the veneers -- onto the substrate (figure P).
  
  

  
  

• On each shelf veneer, using a compass referencing against the template, extend the border 1 inch (figure Q.

  
  

• At the band saw, trim away the excess material on the substrates and on the veneers (figure R).

  Figure Q

  Figure R

  
  

  	Figure S
  	Figure T

  
  

• Now you can veneer the shelves. Begin by spreading an even layer of yellow glue onto one side of the veneer and onto the substrate.

• Flip the substrate onto the veneer, and apply glue to the other side of the substrate and onto the veneer face.

• Set the veneer onto the top (figure S).

• Align the edges of the "wood and veneer sandwich" with blue tape to prevent them from slipping.

• Add the final caul (figure T).
  

  Figure U

  
  

• Apply even pressure using cauls and multiple clamps (figure U). The cauls will provide even clamping pressure to bond the zebra-wood to the substrate.

• Repeat the steps for all three of the shelves.

RESOURCES :

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

Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com