Woodworker's Journal Colonial-Sign, страница 5

Colonial Sign Step-by-Step Instructions

1. Select a 3' long 1" x 6" pine board from which to cut top and base (A), bottom (B), crest (C), blocks (D), and cap (E).

2. Cut off a small piece, slightly larger than final size, to make the cap (E).

3. Use a hand plane to reduce the cap to the required 3/8" thickness.

4. Cut the top and base to length and width.

5. Use the router and a 1/2" diameter straight cutter to cut the groove for the signboard (F).

6. Use a chisel to square the groove ends.

7. Drill the column (H) holes.

8. Establish the 1/2" radius stepped roundover all around.

9. Transfer the profiles for the bottom and crest to the stock for these parts, using the grid patterns as a guide.

10. Use a bandsaw or jigsaw to cut out the profiles.

11. Sand the profiles smooth.

12. Cut the blocks and cap to the sizes shown.

13. Use a 1/4" roundover bit in the router table to radius the edges of the cap.

14. Cut the signboard from a section of 1/2" thick exterior construction or marine-grade plywood.

15. Cut a 1-1/2" square turning block for the columns, being sure to include the tenon lengths plus a little extra when you cut the stock the length. NOTE: The top and bottom halves of the column turning are symmetrical.

16. Cut a 1-3/4" square turning block for the finial (G), again being sure to include the tenon lengths plus a little extra.

17. Use a combination of gouges, a roundnose, and a skew chisel to shape the columns and finial on the lathe.

18. Final sand the column turnings while still mounted in the lathe.

19. Trim the extra stock for the finial and then smooth the top end after removal from the lathe.

20. Purchase a waterproof epoxy for the sign assembly.

21. Glue the crest and bottom to the top and base. NOTE: This is a good long-grain glue joint, but to reinforce the joint we added screws inserted through countersunk holes drilled in the groove bottoms (see exploded view).

22. Glue the two blocks on either side of the crest as shown.

23. Add the cap.

24. Drill for the 1/2" diameter tenon on the finial end.