Then,markandcut theendsof thefrontpieces. I I I I I I 2 Installing thefirstlayerofmolding r-J Eachlayerof molding is fastened to I thearmoire in twosteps: Thelonger strips forthesideandfrontareattached first, I followed bythesmaller pieces around the pilasters.
Spread a thinlayerof glueonthe I backfaceof thefirstsidepiece, thenset it in placeagainst thearmoire withitstop I levelwithor slightly above thetopof the cabinet. Usea cut-offbradasshownon I p a g e1 2 3t o h e l pp o s i t i otnh em o l d i n g whileyouclampandscrew it in placeat I eitherendof thestrip. Foursmallpieces needto befittedaround eachpilaster; miterallthepieces I at 45'at bothends. Holdthemitered endof a stripof the f irstmolding flushagainst themrtered endofthemainfront I piece, thenmarkthefrontcorner of thepilaster ontheedge o f t h em o l d i n gM.
Dry-assemble thepieces to ensure anaccurate fit,thenspread glueonthe p i e c eas n df i t t h e mi n p l a c eS. Thesecond layerof molding cannowbeattached I thesamewayasthefirs1. Setthe blade i n g ,w h i c hc a nt h e nb er i p p e di n h a l ft o p r o d u ct e w oc o r n i c e height at the desired depth of cut,Laytheguide acrossthe blade I moldings. Toconstruct the1ig,fasten twoinch-long 1-by-2s androtate it untiltheblade, turned byhand, just touches the in- to two9-inch-long 1-by-2s withcarriage bolts and wing nuts, edges side of thearms.
Then runa pencil along the insideedges I forming twosetsof parallel arms. Adjust thejig sothedistance of thelongarmsto traceguidelines onthetableinsert above. I r Cuttingthe cove I Z- Remove the suideand lowerthe blade beneath t h e t a b i e. Referto the illustration forsuggested dimensions. I Tobuildthejig,bevel theendsof theguides at 45". Next,cutthebase I andfenceandscrewthetwopieces together,leaving enough of thefence I extending belowthebaseto sit in the slotbetween thefrontauxiliarytable I andthespacer.
Then,remove the saw'sfenceandposition thebaseof t thejigonthesawtable,seating the fencein thetableslot. Posi- tionthebeveled endof thesecond I guideflushalong thekerfinthebase. Usea carpenter's square to ensure I thesecond guideis square to the firstone,thenscrewit in place. Install thejigonthetable. Holding I t h es t r i po f m o l d i nfgi r m l ya g a i n s t oneof theguides, butttheendof I thestockagainst thefence.
Turnon thesawandpulltheyokethrough the I cuI left ,Tocut the matingmiter, secure thesecond pieceagainst the I opposite guide,thenpullthesaw through thecut. First,rip thestockto thedesired width. I Theninstalla dadoheadaswideasthe space youwantbetween thedentils, and I adjustthebladeheight to setthelength of the blocks. Screwan extension board t to themrtergauge, thenfeedit intothe dadoheadto cuta notch. Movetheexten- I sionto therightbythewidthof theden- til,thencuta second notch.
Butttheendof the stockagainst the keyandholdit f irmly I against the mitergauge to cut thef irst d e n t i lF. Thehardware consists I anda threaded rodwitha plasticfoot. Drillthem longer slightly thanthethreaded rods.
Adjustthefeet screwin thelevelers I to levelthecabinet. However, therearedifferences. Boththeinsideand I outsideedges of thestilesandrailscanbe moldedfor addeddecoration. In addi- I tion,themortise-and-tenon joint usedto connecttheframepieces incorporates a I miteredmolding,shownon page A final differenceinvolvesthe stockused I to build doors. Because theyswingfree, doorshavea tendencyto deform.
To I counteractthis, doorsareoften made from heavierstock. To avoidan exces- I sivelyheavyappearance, thebackofthe door framecanbe rabbetedto allow a I portion of thedoor to remaininsidethe armoirewhenit is closed. Theresultins t lip alongthe outsideedgeofeachdooi restson a verticalmullion dividins the I cabinetopeningor on a falsemulTion, whichis a stripofwood attached to the I edgeofthe left-handdoor.
Theglass doorshownon page73is I essentially a frame-and-panel doorwith glass panels. Theglass sitsin rabbets cut I alongtheinsideedges of theframeand isheldin placeby stripsof molding. Theirtip-rabbeted mount- I ingpartly recesses thedoorsinto thecabinet,makingthem appearthin and delicatedespitetheirsturdyconstruction. F i n a l l yd,r i l lm o r t i s ei nst h e stiles sfep5 andprepare eachframefora pan- I el step6.
Tocutthetenons onyourtablesaw, install a dadoheadslightly widerthanthetenon I length. Install anauxiliary woodfenceandnotch it byraising thedadoheadintoit. Setthewidth I o f c u te q u atlo t h et e n o nl e n g t a h n da d j u st th e cuttingheight to aboutone-third thethickness I o f t h es t o c kH.
Turntheboardoverandmakethesamecuton I t h eo t h e sr i d e C. Tocutthe tenonshoulders, setthecuttingheight at about I I tnch. Then,withtherailfacef lushagainst the mitergauge andtheendbuttedagainst thefence, t feedtheworkpiece intotheblades. Turntherail overandrepeatthecut onthe olherside right , I Cuttherestof thetenonshoulders thesamewav.
Alignthefencewiththe bit and I bearing onthebit,thenadjustthecutting depthto shapethebottomportion of the I board.
Foreach good-face-down pass, feed the stock intothe bit, pressing it c u t- I t f i r m l ya g a i n s t tingheight, if h ef e n necessary. Fora median rail, I liketheoneat right, shape both edges. J Thecorners of thetenonshoulders mustbe mitered to mateproperly with t thestiles. Remove theauxiliary from fence thetablesawfenceandinstall a crosscut I orcombination blade.
Settheblade angle to 45', makea testcut in a scrap board, t a n dc h e c kt h ec u tw i t ha c o m b i n a t i o n square. Adjustthefenceposition and t bladeheightsothatthecut is exactly as wideanddeepasthewidthof theedge I molding. Thebladeteethshould justpro- trudebeyond thetenonshoulder.
Tomake I thecuts,holdthe piece flushagainst the mitergauge andthefenceasyoufeedit I edge-down intotheblade. Repeat thecuts ontheendsof eachmolded edgeof the I remaining rails left.
Cutintothemolded edgeat the line,making certain thatthecutwillnot I marthefaceof thestile. Forstilesmat- rngwithmedian rails,youneedto make I twoopposing 45" cutsandsliceawaythe wastebetween them. Sliceoff mostof I thestripof molding between the45" cut andeachendof thestilewitha bandsaw I above. Smooththe cut edgeusingthe tablesaw. Leaving theripfencein place, t holdthestileflushagainst themitergauge andslidethestockbackandforthacross I the blade right.
Repeat the process for a l lt h es t i l e s. Repeatthe process for the stilesof eachdoorandclamptheframeface-down on a work o t h e rp a n e ol p e n i n g sM. M o v e I the routerclockwise alongthe edges far ieft untilthe cut is completed. Periodically test-fit theleaves leafat eachend;bolts fasten the assembly to thearmoire. Begin by secur- oncethe hingerestsflushon theedgeof thedoorwiththe ingthedooredge-up in a vise.
Position thehingeontheedge s. I r Installing thedoor I L to mountthehinpeboltsto the armoire,setthepiecJonits back. Borea clearance holeat I eachmark. Fixthedoorin place withthenutsorovided. Foreach door,fix stripsof masking corners of theopening. Onceyouaresat- I isfiedwiththepositioning, nersof thedooronthetapewitha pencil. Holding I theupperhalfof thehingein place, offthebottom halfandthehingepinand slip t usea pencilto markthescrewholeson the dooredge below.
Check that I thecorners of thedoorarealigned with themarkson themasking tape. Trace t around thebottom of thehinges witha p e n c i lr,e m o vteh ed o o rd, i s a s s e m b l e I the hinges, andreposrtion the bottom halves on thearmoire.
Markthescrew I holes onthecabinet, borepilotholes, and screwthe bottomhalfof eachhingeto I thearmoire below. Remove theshims a n dt a p es t r i p si,n s e rtth e p i n i n t h e I bottom halfof thehinge, andplacethe dooronthearmoire.
I wouldfor lacehinges page Measure fromthe top o f t h e l e a ft o m a r ki t s s c r e wh o l e so n t h e I doorand borecountersunk screwsto f ix the leafto the door. Traceitsoutline onthearmoire, remove the bracket andoin. Thenslidethe I pinintothebracket, checking thattherat- t a i ll i e sf l a to nt h ec a b i n e bt ;e n dt h et a i l I in a vise,if necessary, to makeit sit flat. I r Mounting I thelockand L makingthe boltmortise I Position thelockonthebackof thedoor, sliding thekeychamber in theholein the I door,andfit thekeyintothe lock.
Make surethatthe lockis square to theedge I of thedoorasyoudrivethescrews. To locate the mortise forthe bolt,turnthe I keyto extend theboltandusea pencil to coattheendof theboltwithgraphite. I Retract theboltandclose thedoor. Extend theboltagainst theedgeof the mullion t to markitslocation andusethedrilland a c h i s et lo c u t a m o r t i scee n t e r eodn I t h e p e n c iml a r k l.
Duringthe larcarcase andahingedtop. Dimen- I MiddleAges,chests served asthe sionsvarybutasageneral guideline primaryreceptacles of household consider a lengthof 40to 45inch- I goodsandvaluables. Theywere also es,awidthof i8 to 20inches, anda calleduponto performdoubleduty heightofabout25inches. Thecar- I asa seating place,at a timewhen caseis madefrompanelsof edge- chairswerealuxuryformostpeople.
Thetop features routedwood I oftenadornedthemwith carved Abiscuitjoiner cutsa slotin themiteredend stripsthatareattached withsliding arches andelaborate chivalricand of the blanketchest'smoldedbase. Thebaseis dovetail joints page91 ; or amold- I battlescenes. DuringtheRenais- rabbetedto acceptthecarcaseof thechestand ing canbe cut into its edge page sanceand Baroqueperiods,the thebracketfeet arethenscrewedto the base.
Toprevent thetopfromwarp- I piecebeganto assume someof the ing,andasadecorative touch,wood elements thatarestillusedtoday,includingframe-and-panel battens canbefastened for stiffening page Thetop can I joinery,moldedtopsandbases, andpatterned bracketfeet. Overtheyears,attractive hardware wasadded,suchasbrass Thetechniques for makingbasemoldingandbracketfeet I locks,handles, andescutcheons.
Youmight In ColonialAmerica,thechestwasusuallyplacedat the choose insteadto installogeebracket feet;thesemakea fitting I footof a bedto storeblankets, quilts,andlinens-hencethe baseforbookcases andarmoires aswell.
Installingblanket box nameblanketchest. Today, thepieceis usedto storeevery- hardware isshownstartingon page Theseitemsprovide I thingfromtoysandclothingto books. Manychests arebuilt thefinaldecorative touchandshouldbechosen carefullyto with drawers for additionalstoraqe.
I I t I t I t chest,with itspatternedfeet Thistraditionaldovetailed t and moldedtopand bottom,is basedon a designimport- ed toAmericafrom easternEuropein the18thCentury. C pa7e 26 I I Bracket.
The top and bottom I panelsof rhedrawerassemblyare mount- I ed in stoppedgroovesin thefront and backpanelsof the chest,with a divider to I separatethe openingfor the drawers.
Thelid stayholdsthetopopen I and allowsit to closeslowly to avoiddamagingthepiece. Clampthetopto a worksurface using I woodpadsto protect thestock. Holdthe hingein position, aligning thecenterof I thepinwiththebackedgeof thetop,and traceitsoutline. Next,installa straight I bit in a routerandsetthecuttingdepth to thethickness of the hingeleaf.
Take t careadjusting thedepth;if therabbetis toodeepit willcausethe hingeto bind I whenthelid is closed. Alignthebitover the insideedgeof theoutline, thenfasten I an edgeguidebuttedagainst therouter baseplate. Routthe insideedgeof the I rabbet, keeping the baseplatepressed against theedgeguide.
Makerepeat cuts, I adjusting theedgeguideeachtime,until the rabbetis completed. Thenborepilotholesat the I marks, putthe hingebackin position right ,anddrivethescrews.
Setthetop I onthechest,withthefreehingeleafflat onthetopedgeof theblanket chest'sback I panel. Markthelocation forthescrews, borepilotholes, anddrivein thescrews. Thehinges aremortised I intoboththetopandbackpanelof the chest. Tobegin, clampthetopgood-side I downona worksurface andplacethef irst hingein positiona fewinches in fromone I end,positioning thepinjustofftheback edgeof thetop. Usea pencil to tracethe I outlineof the hinge left.
J Setthehinges in theirmortises in thetop,drillpilotholes, andscrewthemin place above. Next,setthetoponthechest, I markthelocation forthecorresponding hingemortises onthe r Chiseling outthewaste topedgeof thebackpanel, thenchisel themoutfollowtng the I o u t l i n ae n dc u t i t t o t h e L ' l s e a c h i s et lo s c o r teh eh i n g e procedure described in step2, Nowlaythecheston its backon thickness ofthehinge.
Then,holding thechiselbevel up,pare andsetthetopgood-face a worksurface downbehindit. Place I thewaste fromthemortise abovd. Repeat theprocedure to clear a woodspacerslightly thickerthanthetopunderthebackof outtheremaintng mortises. Becareful to cutthemortises no theblanketchestto line-up thefreehingeleaves withtheirmor- I deeper thanthethickness of thehingeleaves to prevent binding.
Borepilotholes andscrew thehinges in place. A jig liketheoneshown at rightwill guarantee fast,accurate I results. Youwill needto equipyour routerwitha straight bit anda tem- I plateguideto makethecuts. I Cutoutthe template, thenattach thefencewithcountersunk screws.
I To usethejig, securethetop of on the edgeandbuttingthe fence square thecorners witha chisel. When thechestedge-up in a vise. Mark againsttheinnerfaceof thetop. Make youareusingthejig to cut mortises I thehingeoutlineontheworkpiece the cut below ,movingthe router in thetopedgeof theblanket chest, andclampthetemplate in position, in smallclockwisecirclesuntilthe besureto securethecarcase to ore- I aligningthecutoutwiththeoutline bottomof the recessis smooth, then ventit frommoving.
Thestockshould alsobewider andlonger thanyouneedsothatYou I canripandcrosscut themolding to size later. Alignthefencewiththebearing I andfeedtheboardintothebitto carve thedesign in onehalfof anedge. Mount I a featherboard on eithersideof thebit t o s e c u rteh ep i e c ed u r i n tgh ec u t.
Flipthe I pieceoverandrouttheotherhalf,creat- inga mirrorcut of the Itrst right. Then I ripandcrosscut themolding to thestze youneeo. Makestopped dovetails ontheends of thetop;cut stopped dovetail rnortises I in thesidemoldings seepage Afteryouhavemadethedovetail joints, I mitertheendsof themolding at 45". Then placethetopgood-face uponwoodshims.
I Spread a thinlayerof glueonthelasttwo inches of thesliding dovetail andthedove- I tailslot,thenslidethemolding intoposi- tion. Next,laysomepaper towelonthetop I to prevent scratches andinstallbarclamps withprotective woodpadsto secure the I molding in place left.
I I t I I r Adding battens L Wnenmolding isattached withsliding t dovetails, it serves to stiffen thetop,elim- inating theneedforbattens; molding that I issimplyrouted in theedgeof thetopdoes notofferthisadvantage. In thiscase, to I prevent warping fromchanging humidity levels, fastentwoor threebattens across I theundersrde of thetop. Cutthestrips of woodfromthesamestockasthetop,mak- I ingthemaboullY,inches wideand3 inch- esshorter thanthewidthof thetop. For I visual appeal, roundoneendof eachbat- t e no n t h eb a n ds a w.
Drrve three screws to fastenit in place right. Io allow I thebatten to expand andcontract, enlarge thecounterbored holes attheendsofthe I woodstripsintoovals; thecenterscrewis t h eo n l yo n et h a ts h o u l b d ed r i v e inn I tight.
Repeat theprocess to mountthe otherbattens. Tltc ltrockct. Foreachcut,alignthesaw bladejustto thewastesideof thecutting t lines left. Usesmooth, evenstrokes, con- tinuing thecutsto theshoulder line. Placethefirsttail boardoutside-face downontheworksur- I f a c e. H o l da p i nb o a r de n d - d o wwni t h its insidefacealigned withtheshoulder I lineof thetailboard, making certain the edges of theboards areflush. Outline the I tailswitha pencil, thenusea trysquare to extend thelinesontotheendof theboard.
I Markallthewaste sections withXs. Then usea dovetailsawto cut Ihelails right. I Angling the board, ratherthanthesaw, makes foreasier cutting. Thensecure the I b o a r de d g e - uipn t h ev i s ea n dc u tt h e wastebeside thetwooutside tails.
Remove t thewastebetween thetailswrtha chisel using t h es a m et e c h n i q udee s c r i b ei nd t step2. Whenyouhavechiseled outhalf thewaste, flipthepieceandf inishthejob I fromtheotherside. Repeat the process to cuttheothertailboards. Therabbets aresawnin two I passes, withtheshoulders f irst,followed bythecheeks. Adjust thebladeheight so I thecheeks willbewideenough to support t h ec h e sw t i t h o urte a c h i nt hg em o l d i n g I cuts;position thefencesoone-third of the stockthickness willbecutaway.
Usetwo I featherboards to support theworkpiece; attach thetable-mounted featherboard to I a s h i ms ot h em i d d l o e f t h ew o r k p i e icse p r e s s eadg a i n st h t ef e n c eF. Thefroni r-,1Workingona flatsurface,position thebaseonthefeetof cornersof thebaseareassembled withmiterjoints;buttjoints thechest,making surealltheouteredgesareflush. At each I aresufficient fortheback. Theconnections shouldbereinforced corner,borefourcountersunk holes throughthebaseandinto withwoodbiscuits, Usea platejoiner to cutslots, thenspread thefootandscrewthetwotogether above.
Placethechest I gluein theslots,insertbiscuitsin thefrontandbackpieces, in therabbetsof thebasepieceanddrivescrews fromunder- andpress thecornerstogether above andclampthem. Because of their I contoured surfaces, thetwohalves of each footarejoinedwitha miter-and-spline joint I page98 ,ratherthana half-blind dove- tail.
Theogeeprofileis cut in threesteps I onthetablesawandtherouter. Beginby marking theprofileontheendof a pieceof I stocklongenough to makeall thefeet. Set up yourtablesawto makea covecut in I thefaceof theboardasyouwouldforthe cornicemoldingof an armoire page I Usea pushblockto feedthestock,mak- passes ingseveral shallow to cut a cove t of theappropriate depth right. Onceyou havemadethecovecut,usea routerfit- I tedwitha rounding-over bit to shapethe corner of theboardto themarked line.
Tosetupthecut,hold theworkpiece onedgeonthesawtable I andadjust thebladeangle to alignthecut- t i n ge d g ew i t ht h em a r k e d l i n eo n t h e I boardend. Butttheripfenceagainst the stock,lockit in place, andsettheblade I herght to sliceawaythewaste. Usethree featherboards to support theworkpiece dur- I ingthecut:Clamp twoto thefenceanda thirdto thetable;thisfeatherboard should I bemounted ona shimsoit willpress clos- erto themiddleof thestockagainst the I fence.
Feedtheworkpiece withbothhands right. Oncetheboard's trailingendreach- I esthetable,moveto theothersideof the tableandoullthestockoasttheblade.
Holdtheflatedgeof theboardagainst theextension t Tocutthebevels, setyoursaw'sbladeangle to 45" andattach andtheendagainst theblockasyoumakeeachcut above.
Install a dado head and I adjustitsthickness to thatof the splines youwill use. Settheangleof the headat I 45oandshifttheriofenceto theleft-hand sideof theblades. Buttthefenceagainst theend I of the stockandlockit in place. Feed eachpiecewith the miler gauge left , I pressingtheendagainst thefencethrough- outthecut.
Sandthe piecessmooth, then I cutsplines fromplywood or solidwoodto fit intothegrooves. Thesplines shouldbe I aslongasthegrooves; maketheirwidth slightlylessthantwicethe combined I depthof twogrooves. Spreadadhesivein thegrooves I andglueup thefeet right ,thenattach themto the baseasyouwouldstandard I bracketfeet page I The handlesstop at a 90" angle to the sidesof the chest,providing a convenient 1 0utliningthelockfaceplate t way to lift the piece.
I Laythecheston itsfrontpanelandposition the lockface-downmidway between thesidesandflushwiththetopedgeof thepanel. Tracetheoutline I above , of thefaceplale thenextendthelinesontothetopedgeof thepanel. I r Routing thelockmoftise I l mis is oneof therareinstances in whichtherouteris usedto makea free- I handcut.
Careandpatience arerequired. Usea woodchiselto firstcut a shallow I mortise forthefaceplate lip in thetop edgeof thefrontpanel. Next,installa I straight bit in yourrouter, setthecutting depthto thethickness of thefaceplate, I andcuta mortise insidethemarked out- line.
Startbyguiding thetoolin a clock- I wisedirection to cuttheoutside edgesof themortise; clearouttheremaining waste I byfeeding thetoolagainst thedirection of bit rotation. Usethechiselto souare the I corners andpareto theline. Measure the distance between theedgesof theface- I plateandthe lockhousing andtransfer the measurement to themortise.
Adjust I therouter's cuttingdepthto thethickness of thehousing andcutthef inalmortise I left. Usethechiselto square anycorners. Test-fit the lockin thecavityandusethe I chisel to deepen orwidenanyof themor- tises,if necessary.
Usea stripof masking I t a p et o h o l dt h eh a r d w a irnep l a c e while youstartthenailsin theirholes. Markthescrewholesonthe panel,remove the lock,andborepilot I holes. Slipthescrews through their holesin the plateandsetthe plateon I topof the lock.
Turnthe keyuntilthe lockengages withthestrikeplate,then I adda stripof masking tapeto holdthe platefirmlyin place. Slowly closethetop I of the chest right untilits underside touches thescrews. Borea pilotholeat I eachmarkleft by the screwtipsand attachthestrikeplateto thetop.
Tracetheoutline of the mountingplate tight. Next,measure the dis- I tancebetween theedges of themounting plateandthe bowl-shaped housing and I transferthemeasurement to themortise. Adjusttherouter's cuttingdepthto the I thicknessof thehousingandcutthedeep- er mortise. Test-fitthehandle in thecavity t andusea woodchiselto pareanyremain- farleft. Repeat theprocedure for t theotherhandle. Here, it nddsa decorntivetortcltto the top ofn blan- I ket chest.
Inlay nurterinlsctm be nrctal, wood verteer,or solid lurrdwood. Fortherectangular groove shown, make 45" miter cuts at the ends I of the inlay pieces. Cut and test-fit one pieceat a time,thenspread a littleglue t ontheunderside of theinlayandinsertit in theslot right ,tapping thestripgently I witha wooden mallet. Commercial band- ingshould be heldin placewith masking I tapeuntiltheadhesive cures. Forshop-made adhesive andbring f lushwiththesurface inlay,usea b e l ts a n d efri t t e dw i t ha 1 2 0 - g r ibt e l t.
I Movethesander forward alongoneinlay pieceIeft andpullthesander backwhen T youreachtheendof thestrip,overlapping thefirstpassbyone-half thewidthof the I belt. Continue untilthesurfaces of thein- layandthetopareflush,thenmoveonto I theotherstrips. Repeat theprocess witha finerbelt or 18O-grit to smooth the I inlayandthesurrounding surface.
Sand commercial banding byhandwitha sand- I ingblock. Because of itssize, frrl cabriolelegs,the scrolledpedi- I the"highboy-or high chestof mentor crownmolding,theflame- drawers-wasconstructed in two and-urnfinials,theflutedquarter I sections: a lowerchestthat suP- columns,andtheshellcarvingand porteda tallerchestwith four or appliedmoldingadorningthescal- I moretiers.
ThetoPlevelwasfre- loped aprononthelowerchest. Attention is also I. Towaing7 or 8 feethigh,the scrsuedto theiarcasesides. Today, eachelement. Building ahighboyisa challenging. Tiranchortheframesto the I 1,ithi1it. As shorvn1.
The backtaceof the top rail is of cachoneanclto thesiclcpanels. The I panels, ancltu'clbackpanclsscparatecl qroovecl to acceptthecarcase top,ancl drau'erfl'aurcsarcnotchcdat thc front 'l'he br.
ThcL shape scrcrvecl to thenr. The it f'eaturestu'ocliviclers anclthreeclrau,- of thecarcase prrgc anclr. Thc firnt postssitin notches cLLt in thecar- er slicles. Oncethefrrcefr-ame hasbeen I n. Thedesign shownabove at topwillyieldan attractive,stable,andwell-proportioned leg,butyoucanalterthepattern to suit I yourproject or copythedesign of an existing legthatappeals to you.
Begindrawing thelegbyoutlining thepostblock. Makeits length equalto thewidthof thelower T railthatwillbeattached to it, plustheheightof thelowerchest's sidepanels. The A distinctivefeatureof QueenAnne widthof thepostblockshouldbeadequate to accepttherailtenon.
Later,it will be I notched page to acceptthequarter columns of the lowerchest. Next,sketch style,the tapering,curyedcabrioleleg I thepadandthetoe,thenthefrontof thelegfromthetoeto theankleusinga french haslongbeenconsidered a challenge point,thediameter curve;at its narrowest of theankleshouldbeabouttwo-fifths for cabinetmakers. But itsgracefullines thestockwidth. Moveonto theknee,sketching a gentlecurvefromthepostblock I canbecut easilyon thebandsawand to thefrontedgeof thetemplate about2 to 3 inchesbelowtheblock.
Thenjointhe smoothed with handtools. I kneeto theanklewitha relatively straightline. Complete theoutlineat thebackof the leg,fromtheankleto the bottomof the postblock above.
Experiment untilyou havea satisfactorydesign. H o l dt h et e m p l a tfel a to n o n eo f theinside facesof thelegblank,making I surethattheendsof thetemplate and t h eb l a n ka r ea l i g n eadn dt h a t h eb a c k I of theoostblockis f lushwiththeinside edgeof theblank. At this point,somewoodworkers prefer to prepare I the legsandrarlsforthejoinerybefore cutting theleg. Otherwoodworkers cutthe leg I firstandthendotheloinery.
Aligning thesawblade justto thewaste sideof themarked line I forthebackof theleg,feedthestockinto theblade. Turnoffthesawabouthalfway I through thecutandremove theworkpiece. Retract theworkpiece, thencutalong thelinefor I thefrontof the leg left ,againleaving bridges to prevent thewastewoodfrom I fallingaway. I C u ta l o n gt h em a r k e ldi n e sb, e g i n n i n g withthosealongthefrontof theleg,then I theback above.
Thistime,complete ihe cuts,lettingthewastefall away. Then I r o t a t teh eb l a n ka n dc u tt h r o u gthh e bridges leftduringyourfirstcuts right. Thensecure thelegin a vise,withthebottom endfac- I ingup,andusea backsaw to cut away t h eb u l ko f t h ew a s t e s u r r o u n d itnhge I outline.
Maketwoseries of cuts,starting withfourcutsstraight intotheendof the I l e ga t t h ec o r n e r tsh, e ns a w i nagr o u n d theendof the legto severthecorners. I Next,secure thelegin a barclamp,lock t h ec l a m pi n a v i s ea, n du s ea p a t t e r n - t maker's raspto roundthecorners of the p a dC.
Usea fileto smooth thepad. Holding thepat- I ternmaker's raspat anangleof approx- imately 45" to theleg,beginbyshaping I thecontour fromthebottomup hbove. Rotate thelegin theclampasneces- I sarysothatyoucanshapethefootall thewayaround. Smooth thesurface I usinga double-cut flatbastard file,then f i n i s ht h ej o bw i t hs a n d p a p eurs,i n g I progressively f iner-grit papers.
I I Shaping andsmoothing theknee Tof inishshaping thecabriole legand I to remove anyblemishes leftbytheband sawblade,smooth thesurface of theknee I witha spokeshave, followingwitha rasp andsandpaper. Holding thespokeshave I withbothhandsat thebottom of a curved edgeof the leg,pushthetoolslowlyaway I fromyou,cuttinga thinshaving left.
Make a series of overlappingpasses, working I withthegrainuntilthesurface is smooth. Turnthelegin thebarclampto cleanup t theotheredges. Usethe raspto smooth an areathatthespokeshave cannotreach. I Complete thejobwithsandpaper. Thelegsaregrooved to I ed and the cavitie-'s for tl-recluar- tainsdustpanelsandisdividedinto sec- accepttl-reentirethickness of theback t c r c o l L r r t t ri lt rse r o u t e di n l l r e p o s t tionsfor threedrau,ers.
Likethedraler panelsandrabbets in thesidepanels. I blocks,thelou,erchestctrnbegluedup. The a dovetailed nith tenor. As I is madeup of four legs,trvoside threesmaillowerdr;ru,elsslidervellrvith- lr,ithtl-reupperchest, thebackpanelsirre panels, trvobackpanels, bottomrailsat out the aid of a s1ide.
Thefiarrestrre separated bv a nr. Oncethelou,er I the front and back,i'Lndtu,o drau,er screrved to bracesthat trreattached to chestis gluedup,kneeblocksarefash- ionedandattached to thelegs pngcI I Cockbeading arround the dralers and the shellcarvirlgandappliedmolding t on the bottontrail areaddecllater.
To MunL complete thechest,thequartercolnrnns I aretnmedandinstalled in thelegnotch- esand,finall1,, a moldedfl'ameis at- I tachedto thetopeclee of thechest. For I a template, placea prece of stiffcardboard in thecorner between thelegandadjoin- I ingrailanddrawa contour linethatcon- nectsthetwopieces. Thesametemplate I canbeusedforallthekneeblocks. Trans- f e rt h e l i n et o a w o o db l a n kt h a ti s a s I thickastheleg,slightly widerandlarger than the area it must f ill.
Place theblank I against the rail and leg so its outstde face is flushwiththeouterpartof thelegand I drawa second lineontheblankusing the legas a guide right. Thegrainof the I blockshould beparallel to thatoftheleg. Saw out the block on the bandsawasvou I did the legs page Applya thinlayer of adhesiveto I thecontacting surfaces,thenholdthe pieces in placewitha clamp.
Usewood I padsto protect the stockanddirect clamping pressure byshaping themto I f it f lushagainst the legs left. Driuea screwthrough thekneeblockandinto I thelegforaddedreinforcement. It is set into rabbetscut I along the inside edgesof the openings. In addi- tion to providing decoration, cockbeading I protects the edgesof veneereddrawer fronts. Makethisauxiliary sub-base large I enough to keepthetoolflatandstable duringtheoperation.
Setthecheston its I backon a worksurface. Starting at the cornerof onedrawer opening,restthe I routeronthechestwiththebitlustclear of theworkpiece. Gripthetoolfirmlywith I bothhands andturnit on,guiding thebit intothewood. Oncethe pilotbearing I buttsagainst thestock,feedthe router toward theadjacent corner,keeping the I sub-base flal right.
Continue around theopening untilyoureachyourstarting I point. Cutrabbets around theotherdraw- er openings thesameway,thensquare I thecorners witha chisel. Thecockbeading is bestshaped I usingmolding cutters onthetablesaw. Do notusenarrow stock;instead, cut pieces I thatareat least4 inches wideandthen ripthecockbeading fromthem.
Install an I auxiliary woodfenceandf it themolding headwithcutters onyourtablesaw. Raise I theheadintothewoodfenceto notchit.
Usea featherboard to secure thework- I piece;screwit to a shimsothatpressure w i l lb ea p p l i eadg a i n st ht em i d d l o e ft h e I workpiece. Makea fewtestpasses with scraostockto setthewidthof cut. Forthe I firstpass,centertheboardedgeovera cut- ter,thenbuttthefenceagainst theface I of thestock.
Holdtheboardflushagainst thefenceandthetableasyoufeedit into I the cutters right. Experiment withdiffer- g idthu e n tc u t t i n w s n t i tl h ee d g eo f t h e I stockis properly rounded, thenshape both edgesof eachworkpiece. Onceall your I stockhasbeenmilled, install a ripblade onthesawandcutthecockbeading from I theboards, making it wideenough to pro- trudebyI inchfromthedrawer openings I whengluedintotherabbets. J Cutthecockbeading to length, miter- ingtheendswiththetablesawora back- I sawandmiterbox.
Thecorners are t joinedwith throughdovetails and theend grain of the tail boardsis thenhidden I with a falsefront. A dovetailedrunner attachedto the bottomglidesalonga I matingslidefastenedto theframe. I I I I joints 1 Cutting thedovetail I I Sizethedrawer partsto fit theopenings in thechests, then routthedovetails, cuttingthepinsin thefrontandbackpieces andthetailsin thesides.
A setof commercial templates like I theoneshown onthispagemakes thejobsimple andensures accurate results. Attach thepinandtailtemplates to backup I boards following themanufacturer's instructions. Secure one of thedrawer sidesend-up in a vise. Clamp thebackup board I to thestock,making suretherearehalttails at either end;the template andbackup board shouldbeflushagainst thework- I piece.
Protecting thestockwitha woodpad,butta stopblock against thedrawer sideandclampit to thesupport boardto I h e l py o ua l i g ns u b s e q u ecnutt s. I n s t a tl h l ed o v e t abi li t a n d template guidesupplied withthejig andcutthetails,feeding I thetoolin andoutof thetemplate slots above.
Se- curethepinboardin theviseandclampthepintemplate to I t h es t o c ka, l i g n i ntgh ej i g f i n g e rws i t ht h em a r k e od u i l i n e. Repeat at theotherendandfor theremaining frontsandbacks. Then I routa groove forthe bottompanelalong theinside of thedrawer. Fita router with I a three-wing slotting cutter and mount the toolin a table. Adlustthe cutting height to I leave thethickness of thedrawer runners youwillmakein step3 below thegroove. I Setthedrawer right-side up thetable on and,starting at themiddleof onedrawer I side,feedthestockintothecutter.
Continue pivoting thedrawer onthe I you tableuntil returnto your starting point. I I I thedrawer runners andslides Q Making I rJ Mounting thedrawers in the highboy requires twoaddrtional components for I eachdrawer: a runner with a dovetailed groove onthedrawer bottomanda match- I ingslidefortheframe.
Prepare therunner f irst;it shouldbeas long as the drawer sidesandthesamethickness as the gap I between thebottom panel and the bottom I edgeof thedrawer. Tocutthegroove in the runner, install a dovetail bit in a routerand I mountthetoolin a table. Set the cutting depthat one-half therunner's thickness. I slideonthetablesaw, Makethematchtng I using stock one-half asthickastherunner.
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