DIY Network

Walnut Computer-Desk, Part 6: Panels Assembly From "Wood Works" episode WWK-711

	In this segment, David Marks completes the base of the computer desk.
	In addition to the case that holds the drawers, the base includes an L-shaped assembly consisting of a rear and side panel.

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In this special two-episode installment of Wood Works, David Marks constructs a contemporary styled computer-desk. In this segment, work gets underway on he L-shaped panel assembly that makes up the back and sides of the desk. Claro-walnut veneers are added to those portions as well.

Tools and materials used in this project:

Claro-walnut stock for veneers
Maple stock
Baltic birch plywood stock
Ebony stock for handles
Maple plywood stock
MDF for templates and mockup
Table saw; cross-cut sled; dado blade
Miter jig
Circular saw
Jointer
Power planer
Band saw
Table router
Biscuit jointer
Drill press
Clamps
Yellow woodworker's glue
Slow-setting resin glue
Glue roller
Hand scraper
Hand plane
File
Razor hand-saw
Cordless drill; Phillips screwdriver attachment
Threaded inserts
Sandpaper, various grits
Straight-edge
Tape measure
Carpenter's pencil
Chalk
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
	Figure B

Panel Assembly

With the drawer-case and drawers complete, the next phase is to build and add the remainder of the base before adding the top. The base includes an L-shaped assembly consisting of a rear and side panel. These parts are veneered in claro walnut, and made essentially following the same techniques that were used to make the sides of the drawer-case.

• At the table-saw, cut the substrate slightly oversized from Baltic birch.

• To begin the veneering process, spread an even layer of plastic-resin glue onto the substrate.

• Apply glue also to a sheet of claro-walnut veneer, and place it on the substrate.

• Balance the substrate by gluing a lesser-grade walnut veneer to the opposite side of the substrate. Align the pieces and secure the edges with tape (figure A).
  

  Figure C

  
  

• Sandwich the veneered substrate between some cauls, then slide the assembly into the vacuum bag (figure B).

  
  

• Once the bag is sealed, turn on the vacuum pump and allow the veneer to cure under pressure for 12 hours (figure C).

• The process for the second panel is essentially the same.
  

  
  

• Once both the back and side panels are veneered, use the cross-cut sled and ripping fence at the table saw to trim them down to final size (figure D).

• To band the edges, apply yellow glue to the walnut strips (figure E) as well as to the bottom edge only of the back panel. On the side-panel, you'll be banding both the bottom and two sides. (The un-banded edge will later be covered by the top.)

  Figure D

  Figure E

  
  

  	Figure F
  	Figure G

  
  
  

• Use tape to "clamp" the banding (figure F), and allow the glue to cure for several hours.

  
  

• Once the glue has dried, use a universal hand-saw to trim the edges, then use a hand-plane and hand-scraper to level the banding flush with the panel surface.

• A dado will be used to join these two pieces together. Using a dado-blade at the table saw, cut a through dado along the back of the side panel.

  Tip: To prevent chipping out the wood at the end, tape a piece of scrap wood to the end of the side panel where the dado will meet the edge (figure G).
  

  
  

• At this point, the L-assembly can be dry-fit to the carcass.

• Before installing the connecting hardware, drill a pilot hole through the carcass to mark where the screws will meet the back panel (figure H).

• Using a doweling jig, drill the holes in the side of the back panel (figure I).
  

  Figure H

  Figure I

  
  

  
  

• Thread the connecting inserts into the holes, then back them back out and apply some cyanoacrilate glue to the threads (figure J) before permanently installing the inserts into the threaded holes.

  
  

• Now the side and back panels can be joined to create the L-shaped assembly. Apply plastic resin-glue to the side-panel dado and to the edge of the back-panel.

• Using two right-angle guides, insert the back-panel into side-panel dado and secure the assembly with clamps (figure K). The L-brackets will help keep the assembly square as the glue dries.
  

  Figure J

  Figure K

  
  

  
  

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