DIY Network

Zebra-Wood Corner Display: Shaped Edges and Assembly From "Wood Works" episode WWK-703

	The curved sides and crest, and the shaped edges, are highlights of this corner display.

In this episode of Wood Works, David Marks fashions a three-tiered corner-display out of zebra wood.

With the shaped sides of the corner display complete and assembled, and the three display shelves covered in zebra-wood veneer, the final steps in the project before applying a wood finish are shaping the edges of the curved shelves and glue-up.

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; #20 biscuits
Jig saw
Spoke shave
Rasp
Chisel
Hand-saw
Hand-plane
Hand scraper
Clamps
Yellow woodworker's glue
Glue roller
Straight-edge
Carpenter's square
Compass
Scribe knife
Measuring tape
Carpenter's pencil
220-grit sandpaper
Blue carpenter's tape
Tung-oil finish
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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• With the banding on the edges of the display shelves glued and cured, David trims the ends off of the zebra-wood banding using a small hand-saw and planes them smooth with a hand-plane (figure A). He then sands the surfaces with 220-grit sandpaper.
  

• With the banding and edges smooth, conduct a dry-fit to ensure that the pieces fit snugly (figure B).

  Figure A

  Figure B

  
  

  Figure C

  
  

• With the pieces in place, work can begin on some final shaping, blending the transitions from the sides to the shelves. A good tool for this is the spoke shave -- a one-piece wood construction with a metal blade that is typically used for rounding or shaping. It's a little like a hand-plane with two handles (figure C).
  

• On the side pieces, trace on a 1/8" line on both sides of the edges, then use the spoke-shave to create the rounded shape using the spoke shave (figure D), a hand scraper and a #50 pattern-maker's rasp (figure E). Use caution to avoid shaping where the shelves meet the side edges.

• With the shelves clamped securely in the workbench, also smooth over their edges using a rasp and hand-scraper.

  Figure D

  Figure E

  
  

  Figure F

• Now glue-up can begin. Apply yellow glue to the front edges of the dados (figure F) and the front edges of the shelves. Gently tap them into place with a dead-blow hammer. The tight fit of the shelves in the dados should be strong enough to hold the shelves secure.

• Allow the glue to set for several hours.

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