| Mahogany Piano Bench -- Assembly |
From "Wood Works"
episode WWK-213 |
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With the legs, feet, apron and stretchers are all made, and have been checked with a thorough dry-fit, the assembly and glue-up of the piano bench can get underway. The glue-up is done in two stages: gluing the end assemblies together (figure A), then joining the two ends with the center section and bottom stretcher. Before glue-up begins, the edges on all of the components are softened using some 120-grit sandpaper. Materials: Table saw
Cabinet scraper
Hand scraper
120-grit sandpaper Yellow woodworker's glue
5-minute epoxy glue
Ruler; carpenter's pencil
Saftety 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: - Glue up the ends of the piano bench using yellow wood-worker's glue. Add glue to both the mortises and tenons (figure B). During this section of the glue-up, make certain that the flat surfaces of the leg are referencing down against the assembly table -- not the tapered surfaces.
- Apply clamping pressure to hold the assembly secure as the glue dries (figure C). Repeat these steps for the other end assembly.
- Once the sides are dry, move on to the center section. Apply glue to the mortises, tenons, rabbets (figure D) and edges of the bottom panel.
- Clamp the entire assembly together (figure E), and allow the piano bench to dry for a few hours.
- Woodworker's Tip: If the piano bench doesn't sit perfectly flat once assembled, here's how to fix the problem. First, make certain that you have a flat, level surface from which to reference. Next, make a homemade scribe by taping a pen at an angle to some shims of wood (figure F). Find the leg that has the biggest gap underneath it, and set your scribe according to that gap. Using the scribe, mark lines all the way around the feet on all four legs. Once you've made the marks, flip the bench upside-down, and level off the high spots using a pattern-maker's rasp.
- With the base assembly complete, take measurements for the top (figure G). As a design consideration, this bench top will overhang the base by about an inch.
- To make the lid for the piano bench, cut a 3/4-inch piece of mahogany plywood to the proper dimensions using the table saw (figure H). The piece should be cut two inches short on both length and width dimensions since the plywood seat is going to be banded with 1-inch strips of solid mahogany for a decorative effect.
- Some 3/4-inch solid-mahogany stock is cut and milled to band the edges of the top. The strips are mitered at the corners to frame the plywood piece (figure I). These bands add to the design, and strategically cover the raw ends of the plywood.
- Glue the mahogany strips to the edges of the top, and apply clamping pressure as the assembly dries (figure J).
- Once it dries, clean up the surface of the seat using a cabinet scraper and hand scraper (figure K).
In the segment that follows, the hinges and wood finish are added.
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RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
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
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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