Creative Woodworks & crafts 2005-11, страница 54

If using the Piexiglas finishing method, run a bead of silicone sealer in the rabbited channel, being careful not to apply too much. {We cut the tube on an angle and used the tip of the tube to force the sealer deep into the channel.) Insert the Piexiglas circle into the frame and apply a light pressure. If any of the silicone sealer oozes out the front, use a cotton swab dipped in rubbing alcohol to remove it. Once the sealer has dried, place the wildlife insert into the frame. Note: do not apply any silicone sealer to the coaster frame if using the Envirotex Lite finishing method.

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Use the No. 2/0 reverse tooth scroll saw blade to carefully cut out the insert design, making the interior cuts first and finishing with the perimeter. Carefully sand the insert pieces using 220 grit sandpaper and then 400-grit sandpaper. (We used a 1/3 sheet handheld orbital sander.) Place the project on a perfectly flat surface, and use very light pressure to sand these delicate designs. When finished sanding, use the vacuum attachment brush to thoroughly and carefully vacuum any dust off the pieces.

Initial Assembly

Place the inserts right-side up on a tray or piece of old board, and spray them with several light coats of satin varnish, being sure to spray them from all angles and allowing cach coat to dry before applying the next. Brush two to three coats of varnish onto the oak cocster frames, sanding after each coat. When completely dry, test-fit the wildlife inserts into the frames, sanding or shaving the edges as necessary.

If using the Piexiglas finishing method, photocopy four coaster patterns and attach them to the Piexiglas. (Leave the plastic protective sheet on the Piexiglas and use temporary-bond spray adhesive to attach the patterns to the protective sheet.) Using a No. 2 reverse tooth blade with your scroll saw set to a slow speed to avoid having the plastic re-melt back onto itself, cut out the circles along the DOTTED lines on the coaster patterns. When finished cutting, remove the patterns and protective sheet, and clean the edges by breaking cway any bumps that may have formed as a result of melting plastic. Clean the surfaces using a soft paper towel, glass cleaner, and very light pressure. Remove the wildlife inserts from the frames, and dry-fit the Piexiglas pieces into the coaster frames to ensure a proper fit. Once satisfied with the fit, remove the Piexiglas peces.

When completely dry, gently sand the edges of the veneer even with the edges of the frames. If using the Piexiglas finishing method, skip to the instructions for Final Assembly.

Flace the coaster frames onto the veneer, and trace along the perimeters. Using scissors, rough-cut the veneer pieces to size, and set aside. Apply a thin coat of clear-drying wood glue to the backs of the coaster frames and the wildlife inserts. (The backs of the inserts and frames should be practically flush with each other, but a slight discrepancy is acceptable because the glue should fill in the difference.) Attach the veneer pieces to the backs of the coasters, place flat boards on each side of the coasters, and clamp the pieces together.

54 • Creative Woodworks & Crafts November 2005