Creative Woodworks & crafts 2000-03, страница 70

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Part Description

Red oak:

A Main slot block B Small slot block C Slot covers

BILL OF MATERIALS

Size in inches

2-5/8x4-5/8x11-1/4 2-5/8 x 4-5/8 X 4-7/8 3/8x4-5/8x11-1/4

Quantity

1 1

2

SUPPLIES

Tools: jointer; thickness planer; band saw; belt or disc sander; table saw; power miter box saw with a carbide blade; router with 1/4"-Dia roundover bit; drill with assorted bits; random orbit or finishing sander; Four rubber floor protectors with screws (approx. 7/8"-Dia.) Franklin's Titebond II (or other water-resistant glue) Sandpaper, assorted grits Tack cloth Damp cloth

Clamps (adjustable hand screws)

Six No. 18 x 3/4" wire brads

Linseed oil

Paint thinner

Spray Deft

Steel wool, No. 0000

,„„ ... .

INSTRUCTIONS

This knife block consists of a long, thick block into which slots have been cut to hold the blades of the various knives. These slots are capped with thinner pieces of lumber to contain the blades within the block. A smaller piece of the thicker stock is then glued to the front of the larger block and is also slotted to hold smaller knives. Finally, the block is elevated off the counter top with non-skid feet.

I chose red oak for the project, but any species of good cabinet grade lumber will work nicely—cherry or maple are excellent alternatives.

Make the slot blanks and covers

Size the stock for the slot blanks and slot covers to the dimensions indicated in the Bill Of Materials. Lay out the two slot blanks and label which sides will be exposed (see Fig. 1).

To make the cuts for the slots, try to use a saw blade with a kerf wide enough to cut the slots to the desired width in one pass. This will make cutting the slots much easier and will ensure uniform-width slots. A 10" blade is recommended here, as it can be raised to the required height of 2-1/8" for the largest slot.

Cut the slots as indicated on the pattern. First cut the slots in the small block, which are all 7/8" deep. Set the table saw blade for this 7/8"-deep cut by drawing a horizontal line 7/8" up from the block's lower edge, then raise the blade until it meets this line (see Fig. 2). Next, cut the slots

in the main block.

Note: the layout of the slots shown was designed for a generic set of kitchen knives. Other accessories, such as shears or sharpening steels, would require a different set of slots. These would have to be designed by the individual craftsperson. Lay out the pattern on paper before cutting any wood.

Assembly

Apply a thin, even coat of glue to the slotted surfaces of the main slot block, and clamp the slot covers in place as illustrated in Fig. 3, Swab any excess glue out of the slots with a damp cloth on the end of a thin wire rod.

Tip: to avoid slippage in the glue joint, which would result in misalignment of the laminated cap boards, drive six small (No. 18 x 3/4") wire brads into the larger board, then cut the nails off as close to the board as possible with diagonal cutters. Once cut, the nails still stand slightly proud. The points that remain are long enough to bite into the thinner board, but not high enough to interfere with the gluing.

Square up the top end of the main block subassembly and true up the edges. Sand the top and front surfaces.

Glue the small block to the larger one. It is offset 5-1/2" down from the top of the larger block. Clamp this assembly and allow it to dry (see Fig. 4).

Cut the knife block to shape

The bottom of the block is cut off at a 15 degree angle. The front surface of the smaller block is also angled. Using the Side View Drawing as a guide, lay out the final dimensions and cut to shape (see Fig. 5 and 6).

Finishing

Thoroughly sand all surfaces of the knife block and round over all edges (except the bottom) with a router and 1/4"-Dia roundover bit.

Apply a solution of boiled linseed oil cut 3:1 with paint thinner. Use this mixture to uniformly darken the wood and to spot any defects such as dried glue or mill marks while they can still be sanded out. Wipe off the excess linseed oil mixture after about ten minutes. Let dry for 24 hours before applying the varnish.

Apply several coats of spray varnish, sanding lightly between coats.

Affix the feet to the bottom of the knife block as shown in Fig. 6. The feet keep the knife block above any moisture on your kitchen counter. We used floor protectors for the feet, which are available at most home centers.