DIY Network

Torsion Box -- Finishing Touches From "Wood Works" episode WWK-409

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This assembly table -- or torsion box -- provides a consistently flat plane that's essential for fine woodworking and furniture-making. The construction of this piece uses methods similar to those used to build airplane wings, and is resistant to twisting and bending under weight. Figure A Figure B Figure C Figure D

The final steps in the creation of the torsion box are to soften the edges, smooth the surfaces and apply a protective finish.

Materials:

Hand scraper
Wood filler
Putty knife
Pneumatic sander
Sanding block; 220-grit sandpaper
Tung-oil wood finish
Paint brushes
Rags

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, power-tools, saws, drills, routers, etc.

Safety Alert: Always wear protective gloves, and ensure adequate ventilation, when working with wood stains, solvents and other toxic solutions.

Steps:

• Use a hand scraper to remove any excess glue from the seams or surfaces outside of the box.

• Since a perfectly flat and smooth surface is essential for the torsion box, all of the nail holes will need to be filled. Use a solvent-based wood-dough putty to fill the holes. Apply the putty using a putty knife (figure A).

  Tip: If you find that the consistency of your putty is too stiff or dry, mix in a small amount of acetone to soften the mixture.

• Once the putty has dried, smooth the surface of the table using a pneumatic palm-sander (figure B). Use the sander to remove the pencil marks as you sand the surface.

• To soften the edges of the frame, use a hand-held router and bevel-bit (set to 3/32-inch) to chamfer both the top and bottom edges of the mahogany trim (figure C).

• Protect the top surface and mahogany trim by applying several coats of tung-oil finish (figure D). The finish will not only enhance the appearance of the surfaces, but will help create a smooth, non-stick surface.

• After the finish has dried, protect and seal it further by rubbing in a few coats of a good quality furniture wax.

We made a base for our torsion box out of 3/4-inch plywood. The base has only three sides, with the open fourth side allowing for storage of tools and materials beneath the surface. Some people simply use sawhorses or old milk crates to support their torsion box. Regardless of which base you choose, make certain that you use shims to level the work surface accurately.

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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

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

How to Design and Build Your Ideal Woodshop
Model: 1558704817
Author: Bill Stankus
Popular Woodworking Books