| Oak Step Ladder -- Assembly |
From "Wood Works"
episode WWK-205 |
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Step-Ladder Assembly With the angled side panels, rosewood-trimmed steps and joinery all made, assembly on the oak step-ladder can begin. Gluing the tenons into the dados would create strong enough joints for most pieces. But because this is a step ladder, the structure is strengthened by using wood screws in addition to the glue bonds to reinforce the joints.
Materials: Cordless hand-drill; screwdriver attachment; Forstener bit
Hollow-chisel mortise bit
Dead-blow hammer
Wood screws or sheet-metal screws
Yellow wood-glue
Carpenter's pencil
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc.
Steps:
- Once installed, the screw heads will be concealed using decorative ebony tenons (figure A). The ebony caps create a nice accent for this contemporary piece.
- The screws and caps are placed 1-1/2-inch in from the front and back of the steps. The locations of the screws are marked (figure B).
- Use a hand-drill and Forstner bit (figure C) to make the holes for the screws.
- With the holes drilled, use a hollow chisel mortise-bit (figure D) and a dead-blow hammer to cut square mortises around the screw holes for the ebony tenons.
- Then, use a sharp chisel to make the mortises square (figure E).
- Since there are few joints, and the elements have been made precisely and dry-fit, the glue-up is fairly simple. Apply woodworker's glue into the dados, and brush some on the tenons.
- Assemble the pieces carefully (figure F), and tap them secure with a dead-blow hammer. Clamping is not necessary since the wood screws will tighten the pieces together snugly.
- For added strength, use #10 sheet-metal screws to fasten the pieces securely (figure G).
- Once the steps and side pieces have been fastened together, add the top (figure H) and secure it in the same manner as with the sides -- pre-drill the screw holes, cut and chisel the mortises, add some glue, and screw the top step in place.
In the segment that follows, the ebony accents and wood finish are added.
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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
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
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
Beds and Bedroom Furniture: The Best of Fine Woodworking
Model: 1561581917
Author: Editors of Fine Woodworking
(1997)
The Taunton Press Inc.
Website: www.taunton.com
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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