Popular Woodworking 2008-06 № 169, страница 37
Level the slats. I use my ancient (and very loud) belt sander to level the slats. This operation requires a light touch and good hearing protection. Perfect slices. After machining a piece of ebony to I" x I" x 12", slice 16 '^"-spacers at the band saw. And make a few extra, just in case. along with the notches in the bottom rails. Test-fit and clean up the notches with a shoulder plane or chisel. With the notches completed, machine the curved edges of the keel slat and stretcher, repeating the process used for the slats - i.e. band saw, template-rout, cut to length and sand smooth. Make a simple jig with a 30° notch as shown at left below. Use the slat template and jig to set up your drill press. Drill 5/i6" holes in the slats. Note that the two outside slats also receive V2"-deep counterbored holes, centered on the previously cut5/16" holes. Use a Forstner bit for these counterbored holes, and drill them while the slats are still in the clamps. When al 1 the slats are dril led, gang i he slats together, secured with two 1/4"-20 threaded rods (about 15" long) and corresponding 'A" washers and nuts. Number the slats for later reassembly and sand them as a unit, first with a belt sander and finally with your random-orbit sander (ROS). Next, ease the edges with a 3/16" roundoverbit at the router table. As before, pay attention to grain direction. Finally, sand all slats individually with your ROS working up to #220 grit. (I find that Mirka's Abranet does a quick job on this tough wood.) There should be no sharp edges, except for the notches in the keel slat. I finished the process by hand-sanding with #600 grit. Machine a piece of ebony to 1" x 1" x 12" and slice 16 V2"-spacers at the band saw. Each spacer receives a 5/i6" hole, centered by using a jig. This is a critical operation as the spacers must align perfectly during assembly. While at the band saw, cut four Vs'-long ebony plugs using a 5/a" plug cutter. Also cut four jatoba plugs, which will be used later. The top is now ready for assembly. Add Top assembly. To start assembly, insert a rod through one of the outside slats so the washer and nuts are recessed in your counterbored holes. Slide on a spacer. Repeat. washers and nuts to one end of the two threaded rods, with the nuts threaded just enough to be flush with the rod ends. Insert the rods through one of the outside slats so that the washer/nut combinationsare recessed in the counterbored holes. Slide a spacer onto each rod, add a slat and repeal until all the slats are in place. Add the washers and nuts to the other end of the threaded rods and snug the short end using a 7/16" nut driver. (I discovered that not Jig and drill. Drill5/16" holes in the center of the spacers. I made a simple bird's mouth, along with a 90° jig, to secure the spacers during this operation. |
