DIY Network

Manly Mantelpiece: End Caps and Secret Compartment From "Freeform Furniture" episode DFFF-106

Host Amy Devers finishes the end cap and works on the secret compartment. She also puts a bevel all around the mantel and a round-over along the edge.

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Amy works on the secret drawer for the mantle that is perfect for storing valuable items.

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
	Figure F
	Figure G
	Figure H
	Figure I

End Caps and Hidden Compartment

1. Cut the end caps to width, and then drill some holes in the ends for the dowels that will attach the end caps to the mantel. Simply hold the end caps against the ends of the box and strike a line (figure A). At the table saw, cut the end caps to length using a crosscut sled.

2. Now drill the dowel holes in the end of the drawer.

3. Use a hand-held drill to drill the holes in the drawer (figure B) to attach the end cap.

4. Mark for the dowel holes in the end cap. To do that, use dowel center pins (figure C). Put the dowel pins in the end of the drawer and slide the drawer into the mantel.

5. Line up the end caps to the end of the mantel.

6. Place a clamp against the end cap, and from the other end of the mantel place a long stick through the center of the mantel and tap the stick with a mallet (figure D) against the back of the drawer. The points on the end of the dowel pins make a center mark in the end caps.

7. Mark the other end to the mantel to receive the other end cap.

8. Using the marks as a guide drill the holes in the mantel , insert the pins in the holes (figure E), clamp the mantel to the bench, line up the end cap over the pins, and tap the end cap using a mallet. Hammer directly onto the end cap.

9. On the drill press, drill the dowel holes in both end caps using the pin marks as a guide.

10. With the depth set on the drill press, drill holes for the secret compartment (figure F) using two different-sized forstner bits.

    Note: A forstner bit is a drill bit specifically designed for cutting large, round flat-bottomed holes.

11. Change out to a different-sized forstner bit as you move to another smaller hole. It is important to do this before gluing on the end cap so you will have a flat surface to drill into.

12. Dry fit the end caps to the drawer and the end of the mantel.

13. It is now time to put a bevel on the mantel. With the blade set at the proper height, set the angle of the blade to six degrees using a bevel gauge. Lock it into place so that you can transfer the angle to cut each piece. Cut the bevel on the end caps first (figure G).

14. Since the caps are not glued on yet, tape them in place.

15. Cut the bevel on the front edge of the mantel as well as the support pieces for the bottom of the mantel. Put a round-over along the edge with a router and a round-over bit (figure H).

16. Put in the V-groove (figure I). You can do it in two parts with a chamfer bit. If you don't have a router table, you can do it with a hand router.

17. With the chamfer bit set at the proper height, run the end caps over the cutter creating one half of the V-groove.

18. With the mantel lying flat on the router table, cut the other half of the V-groove into it.

19. Change out the chamfer bit for the round-over bit. Adjust the round-over bit to the proper cutting height, and cut the round-over on the top edge of the mantel and the end caps. The chamfer creates the perfect V-groove and the round-over really softens the edge of the mantel nicely.

20. Mill out the back of the mantle and the support for the panel clip.

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