Creative Woodworks & crafts 1998-03, страница 16

wood*

Nighllighl

designed by Dirk Boelman

SUPPLIES

Wood: red oak— 3/4" x 6-3/4" x 30" (for the case) and 3/4" x 5-3/4" x 11" (for the base); black walnut—3/4" x 6-3/4" x 20° (for the case) and 1/4" x 6-1/2" x 18" (for the overlays); Baltic birch plywood—1/4" x 12" x 12" (for the silhouette, rear panel and inner support block); 3-1/8" length of 1/4"-Dia. doweling Tools: scroll saw with No. 2/0 and No. 7 or 9 blades; drill with bits including a 13/16"-Dia. and a 1-13/16"-Dia. Forstner bit; stationary belt sander; router with roundover bit; drill with bits; countersink; awl Temporary-bond spray adhesive Sandpaper, assorted grits Glue Buddy wood glue* C-clamps

1/8" x 6" x 12" sheet of white Plexiglas'

2"-Dia. clock insert'

6' cord with candelabra socket and switch* 4 watt clear bulb*

Four No. 6x1" flathead wood screws Six brass nails

'Available from The Art Factory PO Box 701, Platteville, Wl 53818, (608) 348-8332.

Four other designs are also available from The Art Factory for this nightlight: "Nativity", "Cow Jumping Over the Moon,""End of the Trail," and "Sailing Ship." Get all four for just $12.95 including S&H. And for a limited time, get a FREE 6' cord with candelabra socket, switch, and a 4 watt dear bulb with your pattern purchase! (Free accessory offer good through April 30, 1998.)

INSTRUCTIONS

Make the case

Make five copies of the case pattern, found in Full Size Pattern Section No. 1, and affix with temporary-bond spray adhesive to the 3/4" oak and walnut. Cut out each pattern with a No. 7 or No. 9 blade. After sawing, remove the pattern and touch up each piece with sandpaper. Next, alternate the layers of contrasting woods and glue together. Clamp this assembly for several hours to allow the glue to set up. The pieces are not going to be sawn exactly alike, so the best way to shape and finish off the surface is to use a stationary belt sander. After sanding, round over the sharp edges on the front and back by hand sanding.

Make the base, panels, and backing

Cut the base to Ihe dimensions indicated in the Supplies list. Use a router and roundover bit to round the top edges of the base. Fasten the case to the base with glue and four countersunk No. 6x1" flathead wood screws (see the Cutaway View Drawing).

Size the bottom support piece to about 3-1/8" x 7-3/4" and glue the upper support doweling and the bottom support piece in place as shown. Size the 16

overlays to the dimensions indicated, then slightly round over the edges with sandpaper. Next, cut the front and rear panels, using a No. 2/0 blade for the veining and interior cuts on the wildlife pattern and the appropriate Forstner bits where indicated. For the eyes and the ear on the coyote, drill holes with a very small drill bit and follow the pattern lines as carefully as possible. Sawing out too little wood is better than too much for these tiny areas.

Cut the Piexigias and assemble the nightlight

Affix the Plexiglas pattern to the top of the protective film that covers the Plexiglas. Saw the Plexiglas pattern with either a No. 7 or No. 9 standard tooth blade and saw at a relatively low speed. Note: for helpful hints on sawing Plexiglas, see the Plexiglas sidebar on page 22 of Creative Woodworks and Crafts, Feb. '98. After sawing, remove the protective film and the pattern, then dry assemble all of the pieces.

Before final assembly, touch up and sand where necessary. Next, apply the finish of your choice and allow to dry.

Install the cord with the candelabra socket through the back panel. You will need to flip over the plastic nut that holds the socket in place to get the threads to line up and hold securely. Set the back panel into position inside the case. Position the overlay and carefully mark locations for