DIY Network

Walnut Computer-Desk, Part 7: Top Assembly From "Wood Works" episode WWK-711

	The computer-desk's top is built from Baltic birch and veneered in claro walnut.
	Before installing the top, and with the desk's drawer-case and L-assembly complete, David Marks checks the base components for proper fit.

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In this special two-episode installment of Wood Works, David Marks constructs a contemporary styled computer-desk. In this segment, the top of the desk is made, covered in veneer to match the rest of the desk components and joined to the base.

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

Top Assembly

The top is created in the same manner as all of the other panels in this project -- by veneering two sheets of walnut onto a Baltic-birch substrate. (See the first two segments in this episode for details on the process of making and veneering the panels. Links to those segments are at the bottom of this article page.)

• Once the veneering of the top was completed, David took the top panel to a local door-maker's shop so that it could be sanded smooth on a wide-belt sander (figure A). The process of sanding this large surface by hand could take several hours. With this specialized piece of equipment, the process was completed in a few minutes.

• Once sanded, trim the veneered top to size using the table saw (figure B).
  

  
  
  

• At the band saw, cut 1/2" strips from a long piece of claro walnut to make the edge-banding for the top (figure C).

• After checking for exact dimensions, use the table saw and miter sled to miter-cut the ends of the edge banding (figure D).

  Figure C

  Figure D

  
  

  
  
  

• To attach the edge-banding to the top, apply glue to the claro-walnut strips and to the edges of the top.

• Once all of the banding is in place, insert some cauls around the top and bring the banding snug to the edges using a band clamp (figure E). The cauls will protect the walnut from the clamps.
  
  
• Tighten the band clamp, then apply even clamp pressure all the way around (figure F).

• Once the top is dry, use a hand scraper to level the banding with the surface.

  Figure E

  Figure F

  
  

  
  

• The base of the computer desk can now be joined to the top. Along the top edge of the L-shaped assembly, use a cordless drill and Forstner bit to drill seven holes to accommodate figure-8 fasteners. Secure the fasteners in place (figures G and H).

  Figure G

  Figure H

  
  

  
  

• For strength, the figure-8 fasteners in the L-shaped assembly will be used in conjunction with threaded inserts over the carcass (figure I).
  
  
• With the top flat on the assembly table, position the carcass and the L-shaped assembly upside-down (figure J). Essentially, the base should be centered side-to-side, and about 1/2" from the back, leaving more room in the front.

• Once the pieces are in position, mark the locations for the matching figure-8's and the threaded inserts on the top.

  Figure I

  Figure J

  
  

  
  

• Use a cordless drill and centering bit (or vix bit) to pre-drill the holes for the screws(figure K).
  
  
• As before, install the threaded inserts, first coating the threads with cyanoacrilate glue (figure L).

• Once the glue has dried, use a hand scraper to remove the excess.

  Figure K

  Figure L

  
  

  
  

• Now you can confirm the fit of the entire assembly by attaching the base to the top (figure M).
  
  
• With the components attached, turn the completed desk upright (figure N)..

  Figure M

  Figure N

  
  

  Figure O

  
  

A useful option for the computer desk is a keyboard drawer to free up even more space on the work surface. It can simply be attached with screws beneath the desktop surface. David opted to add one, matching the design of this desk. It's an elaborate design, and covering its construction might require another complete Wood Works episode, but a summary description is below. The techniques for building it are based on principles already covered in this project.

The basic system is a "box within a box" (figure O), similar in design to the drawers and dividers made earlier. The casework is made from 1/2" maple joined using half-lap joinery.

• There are two frames -- a top and bottom frame. The bottom frame has three runners -- one in the center and one on either side (figure P). There is an opening at the back to allow for electrical and keyboard wires.

• There are spacers around the entire perimeter of the bottom frame for attaching it to the top frame. The two halves are attached using biscuit joinery (figure Q).

• Once the assembly is put together, the front edges are capped with walnut banding.

  Figure P

  Figure Q

  
  

  
  

• The drawer itself (figure R) is made from 1/2"-thick maple and dovetailed at the back. A stop-dado is cut in along each side (figure S) to allow for runners.

  Figure R

  Figure S

  
  

  Figure T

  
  

• The drawer-front is made from solid claro-walnut, and veneered on its front surface with curly claro-walnut. The front drops down so that the keyboard can slide out. A solid maple cap, glued along the front edge of the plywood bottom, provides part of the anchoring point for hinges that are mortised in at either end of the drawer front (figure T).

In the segment that follows, David creates hand-sculpted ebony drawer-pulls and adds a wood finish that brings out the striking figure of the claro-walnut grain.

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