DIY Network

Manly Mantelpiece: Cutting Ends for Drawer Front and End Cap From "Freeform Furniture" episode DFFF-106

Host Amy Devers introduces the finished mantel. She uses a table saw and cross-cut sled to remove the ends off for the drawer front and end cap. She then uses a band saw to cut the front, back, top and bottom and uses the planer and joiner to further mill the wood.

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	Before shot of the mantle.
	After host Amy Devers worked her magic!
	Amy cuts the ends off for the drawer front and end caps in this first segment.

Materials:

Walnut
Z-clips (panel clips)
Pencil
Tape measure
Dowels
Clamps
Masking tape
Yellow glue
Cauls
Dowel center pins
Long stick
400-grit wet-dry sandpaper
Tung oil
Damp cloth
Paint
Glue
Flocking
Flocking gun
Small paint brushes
Safety glasses
Screws
Large forstner bit
Small forstner bit
Chamfer bit
Round-over bit
2" straight cutting router bit

Tools:

Table saw
Cross-cut sled
Band saw
Planer
Jointer
Dado blades
Drill
Jig
Mallet
Awl
Drill press
Bevel gauge
Router
Fence

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

Cutting Ends for Drawer Front and End Cap

1. The hidden drawer will slide out from one end of the mantle. The other end of the mantel will get an end cap that matches.

2. The first step is to cut the ends off for the drawer front and the matching end cap.

3. Use the table saw and the cross cut sled to do this. A cross cut sled holds the work piece at a fixed 90-degree angle to the blade (figure A).

4. Next, mark out the wood for the pieces to be cut on the band saw.

5. Cut the front and back off first and then cut the top and bottom off (figure B).

6. Save the core (center piece of wood). It will become the drawer.

7. To get rid of the saw marks, use the planer. The planer's main purpose is to mill wood to a uniform thickness. The wood is pulled through the machine and the surface is sheared off by a cutting head with three long blades. You just want to shear off the saw marks, so you only need to send it through once.

8. Since the thickness of the top and bottom is different than the front and the back, set the planer to cut the top and bottom first. Adjust the bed to the desired height, then feed the wood through the machine (Figure C).

9. Now readjust the bed to plane the front and back of the mantle.

   Note: When using the planer, try not to cut too much off at one time.

10. The core has saw marks on all four sides and you need to clean up at least one face in order to put it through the planer.

11. You can use the jointer. The jointer operates on the same principle as the planer, but instead of the wood being pulled through the machine, you push the wood over the top of the cutting head (figure D).

12. The in-feed table adjusts for the depth of cut, and the out-feed table is at the same height as the cutting blade. That way you get a uniform, flat surface for the planer.

13. When pushing the wood through the jointer, apply even pressure over the cutting head and onto the out-feed table (figure E).

14. Using the flat side created on the jointer as a reference, mill the saw marks off the other side of the core using the planer. This insures a uniform thickness.

15. The pieces for the box part of the mantel are cut and the saw marks are planed off.

In the next segmetn Amy works cuts the dados and works on the drawer guides.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Flocking
Donjer Products Corp.
Website: www.donjer.com

Hardwood
Macbeath Hardwood Co.
Website: www.timberproducts.com