Monday, January 28, 2008


Yesterday the dados were cut in the frame rails and stiles. Since there's a center stile (which has already been doweled to the top and bottom rails), the dados needed to be "stopped". The round slot cutter leaves an arching cut at the end of it's travel, so the stopped dadoes need to be squared up by hand. The panel will conceal them, so appearance isn't important.

The panels are more than 24" wide, and all 4 together consume almost 8' of length. This means there's no room for "spares" in one ($95!!) sheet of plywood. Hardboard is cheap, so templates were made to tweak the fit - a good thing, too, since some planing and fitting was required.
Not having enough hardboard of sufficient width to make the templates, the table saw cover was sacrificed. Obviously it was well-used and ready to be replaced, so it was cut up to make the template for the large panel. Since both assemblies are symmetrical, only one of each size is needed - but fit was verified in both sides just to make sure before cutting up the spendy stuff.

The frames are finally filled with panels.
The top rails capping each assembly are glued laminations - some stock is re-sawed to produce several thin strips, which are then glued up in to a sandwhich, and clamped in a form to dry in the proper shape. I'll have to get some pics of them in the forms.

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