| Contemporary Wall Mirror -- Frame Template and Cherry Stock |
From "Wood Works"
episode WWK-301 |
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In this episode of DIY Wood Works, host David Marks constructs a contemporary cherry-wood wall-mirror. With its circular frame, hidden joinery and decorative keystone accents of African wengae (figure A), this mirror embodies the spirit of contemporary woodworking. The perfect circle of the solid-cherry frame, the hidden joinery and recessed wedge-shaped accents present some interesting woodworking design challenges. Materials: MDF for template
Cherry stock
Multi-router; 1/4" carbide spiral router bit; trammel arm
Radial-arm saw
Table saw; mite jig
Table router; 1/4" 3-wing slot-cutter bit
Jointer
Planer
Large woodworker's compass
Double-stick tape
Wood scraps for spacers
Yellow wood glue
Clamps
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his website -- information below under Resources. Safety alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc. Safety goggles are particularly important when using any power tools. Round Template The first step is to make a round master template that is 30" in diameter. Half-inch MDF cut to a piece approximately 31" square is laid out with intersecting cross-marks that designate the center-point. - A large compass, set to make a circle with a 15" radius (figure B), is used to draw the outer circle.
- Once the outer circle is drawn, reset the compass to a 12" radius and draw the inner circle (figure C).
- To cut the template, use a router attached to a trammel arm (figure D). This shop-made trammel arm is basically a piece of 3/4" plywood that serves as the base for the router. The trammel arm is attached to the MDF using a screw in the center.
- Tip: It's a good idea to have the MDF for the template raised slightly above the tabletop for making these router cuts. Use double-stick tape and some wood spacers to support the template and hold it securely above the work surface.
- Install a 1/4" carbide spiral bit in the router and, with the trammel arm attached, simply follow the arm around the template to make the outer cut. The trammel arm keeps the router lined up and holds it in position to cut the outer circle (figure E).
- To cut the inner circle, reset the arm by moving it 3-1/4" toward the center. The extra 1/4" compensates for the diameter of the router bit.
- The second cut completes the round master-template (figure F) that has layout marks in each quarter. MDF generally cuts so cleanly that sanding is not required.
Frame Stock The next phase is the cutting and milling of the frame stock. To create the round frame, an 8' raw plank of solid cherry will be turned into a circle. Here's how it happens: - To begin the transformation, the 8' board is first cut into four 2' lengths using a radial arm saw (figure G).
- For the wood grain to match all the way around the circle in the finished frame, each board is numbered with a chalk mark indicating the order in which the boards were cut. The boards will be kept in that order as the frame is constructed.
- Since the stock is cut from a rough plank, the pieces must then be milled to give flat faces and edges that are a perfect 90 degrees. Start by flattening one surface on the jointer (figure H).
- With one surface flat, that face can be referenced against the fence of the jointer to run the edge of the board over the jointer (figure I) resulting in 90-degree edges. (The second face and edge will be dealt with in steps that follow.)
- Repeat the steps involving the jointer on each of the four pieces of stock.
- Before running each of the boards through the planer, transfer the numbers of the boards onto the flat faces that were just jointed. Use that flat face to cut a flat surface on the opposite side of each board using the planer.
- Finish milling each of the boards by trimming the opposing edges parallel using the table saw.
- The result is four boards, each of which is 7/8" thick by 7" wide by 24" long (figure J).
- The boards can now be joined together, using hidden joinery, to create a 24" square. Use the round template to determine and mark where each of the 45-degree miter cuts will need to go to make a square frame. The joints should be at the four axis-points of the circle, and there should be about 1/4" excess. The boards are centered between the two axis points on the template, and lines are drawn to indicate the cuts (figure K). Once the marks are made on one of the boards, the other three are simply cut the exact same way.
- Make the angled cuts on each board, use a table saw equipped with a miter jig. The result should be four boards identically cut with 45-degree angle cuts at either end (figure L).
- Lay out the boards to form the square (figure M), making certain to line the boards up in the numbered order indicated by the chalk marks made earlier. In this way the grain will match.
- Check the layout to make certain that it is perfectly square.
- The corners are joined together using splines and slots. Cut a slot on the end of each board at the router table using a 1/4" 3-wing slot-cutter bit. This bit has a bearing that references against the wood and, once the height has been set, cuts a slot in the center of the stock (figure N).
- The splines are made from solid cherry. Cut them so that the long grain of the splines matches the long grain of the frame stock (figure O).
- With the slots cut and splines milled, the frame can be dry-fit to ensure a good fit and then glued up using yellow wood glue. Apply even clamping pressure to hold the assembly secure as the glue dries.
In the segment that follows, the square frame is cut and milled into a perfect circle of solid cherry. Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
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
The Complete Woodworker's Companion
Author: Roger Holmes
Publisher: Watson-Guptill
ISBN: 0823008665
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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