Monday, January 8, 2007

A Busy Sunday

Cutting the Tenons
The next step was to cut the tenons. There are many ways to do this this. I decided to take a scrap piece and use the table saw to determine how much waste to remove. I do not have a tenon jig so I determine the correct height of the blade and made several cuts to remove all of the waste. This worked well but did create a lot of dust which always gets to me. I might use a different method in the future due to the dust.

Once they were cut on the table saw, I then had to clean them up. I started with using my block and shoulder plane to clean them up. One issue I noticed is that I was taking off more wood on the side closest to me and I had a little bit of tear out on the ends. After a couple of tenons I then decided to use my chisel to pare in from the end. This worked much better. I also had to clean up the mortises slightly but was able to get them all to fit. Some are not as pretty as others but it will work.

Here is a picture of me cleaning up one of the tenons.

Cutting the Table Round
After the tenons were complete I decided to cut out the table top as I had the half inch blade already installed on the band saw. To do this I had to make a jig. Luckily, I had a scrap piece of plywood and a runner that fit perfectly in the miter slot.

I first measured out the narrowest part of the top and then found the center point. I then measured the same distance from an opposite edge and crossed the lines to drill a pilot hole on the back side of the table. This hole will ride in a dowel attach to the jig.

To make the jig I measured the distance of the miter slot from the blade and attached the runner with a couple of wood screws. I then marked the distance for the center point and drilled a hole and attached a dowel.

Here is a picture of the jig.

I then placed the top onto the jig, turned on the band saw and spun it around for a perfect circle. My wife came out to the shop to hang out and took the following pictures. Otherwise, I would never be in the picture.

Lower Stretcher Profile and Half Lap
To complete the lower stretchers I had to cut the half laps and profile. The half laps I did on the table saw marking the distance and depth. This was not too difficult.

To complete the profile I had to change the band saw blade to a 3/8" blade and I made some practice cuts. I then made the cut and used the fence once I did one profile to cut a straight line to the next profile. I also attached the both stretchers with two sided sticky tape and cut them at the same time.

The profile came out ok but did need some clean up. I used a bastard file along with the waste pieces and a hand made sanding block to clean them up.

Upper Stretcher
The final step was to cut the dovetails for the upper stretchers. I first cut the tails on the stretcher by marking them and cutting a small line in from the side. I then found it easiest to use my chisel to pare down the tail rather than cutting it.

Once complete, I marked them on the legs and number each one. I then used my hand saw to cut the lines and the drill press to remove most of the waste. I then had to use my chisel's to clean up the rest.

Once again, the first couple did not come out as good as the last two. Luckily these are hidden from view as they are not the prettiest.

Here is the table stand ready for the tenon pins, glueing and sanding.

And how it will look with the top (Not attached yet)

No comments: