Woodworker's Journal fall-2008, страница 31

clamped them with handscrews. When they were dry, I glued the middle strip onto one of the outer pairs and clamped again. Finally, I glued the two-strip and three-strip halves together along the last joint, drawing the halves together with pipe clamps set on a plywood panel to just beyond flush and clamping down with handscrews at the ends between the door and the underside of the plywood to bring the joint tight.

The sanding block worked just as 1 hoped it would, sharpening the arrises nicely and smoothing out the blade marks in the coves with 60-grit paper and polishing with finer grits through 220. Lacewood has a coarse texture that doesn't really require anything beyond that. I then trimmed the edges of the finished door. It was important to have the extra width there for this operation, so the blade could skim the high point of the outer arrises while cutting a clean edge all the way to the bottom.

challenge

was how to get the coves' arrises sharp after glue-up. I knew I would need a cylindrical sanding block because the coves coming off the saw would be rough and need lots of smoothing. What I figured out was that if I had a sanding block with a radius just slightly larger than the coves', it would bear against the edges first, before bottoming out in the coves. If I could cut the coves to the proper radius and keep the edges narrow enough, the sanding process would essentially abrade from the top down, sharpening the arrises before smoothing the coves.

That was the theory, anyway. A friend gave me a stout cardboard mailing tube with removable plastic flush cap ends that I thought might work. The walls were almost 3/16" thick, and I found that I could cut it down to a suitable length and attach sandpaper with thumbtacks. The end caps kept it quite stiff. A perfect and simple solution to a challenging sanding problem.

Raising a , Sharp Point 1

A 1/8" strip of hardwood, flexed on his workbench, provided a perfect offset for the top and bottom and made it easy to transfer The curved shape.

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