Datasheet

fiGtue
and clamp a
filler in
the
groove
tlfin
each back rail
(K),
centered on
their
lengths. Assemble
the two backrails
with t'wo slats
pushed
tightly against the
glued-in
fillers. Add the other slats, spac-
ing them approximately 3" apart. Lay out
three bar clamps, and
place
this assembly
on them.
Make
certain the
rails' ends
align,
and snug
the center clamp. Staning
in
the
middle
and
working
out to
the
ends,
glue
and clamp the fillers in
place,
drawing the successive slats and
fillers
toward the center and
tight
against
each
other.
Cut
the four end fillers to fit flush
with
the ends of the
rails,
and
glue
and
clamp them
in
place.
Now
tighten all
three
bar
clamps.
Now
for final
asserrrfrry
I
Place
the shelf
(J)
upside down on
I
your
workbench.
Glue and clamp the
front shelf
skirt
(H)
to the
shelf,
IVc" rn
from
the shelf s
front
edge, where shown
on Drawing
3,
and centered end to end.
Glue and clamp the
front
seat skirt
(I)
to
the seat
(J)
in
the same
position.
Set
assembly UJ aside.
)Ctamp
the assembled shelf skirt
Er
and shelf
(H/J)
between the end
assemblies with bar clamps, seating
f,chieving the
(almost)
invisible
plug
When developing the deSign for this
project,
we
were concerned that the
end assemblies and arms with all
their
plugged
countebores
might look like
Swiss
cheese.
To
prevent
that,
project
builder Chuck
Hedlund
took
great
care
in
selecting and
installing
the
plugs,
shown
in
the
photo.
Here
are
some of
Chuck's tips:
.
Drill
your
counterbores
with
a
sharp
brad-point or Forstner
bit.
Whenever
possible,
use
your
drill
press.
.
Save cutoffs
from
the
parts
that
need
plugs.
Cut
the
plugs
from these
pieces.
.'Use
tapered
plug
cutterc. With these
your plugs
willfit tightly,
like
corks
in
botdes.
.
Cut
more
plugs
than
you
need. This
allows
you
to select
plugs
that
best
match the wood
grain pattern
and
color around the countefuore.
46
.
When installing the
plugs,
take
care
to align the
plug's grain
with that
of
the
surrounding wood.
the shelf's
ends in the end assemblies'
bottom dadoes. Position the shelf so
the skirt
is
3/q"
back
from the end
assemblies'
front edges. The shelf
pro-
trudes Vz" beyond the front uprights.
QCtamp
the rear
shelf skirt
(H)
in
place
{3/+"
in from
the end assemblies'
rear
edges. Using the shank holes
in
the
end
assemblies
as
guides,
drill
pilot
holes into
the shelf skirts.
Drive in the screws. To
allow for wood movement, do
not
glue
the
rear skirt to the shelf.
/
Retrieve the seat assembly
(VJ).
tf
Chmp
a 13x13" scrap spacer to
the
inside face of one end assembly
with its
bottom
edge on the shelf. Its top edge
is
even
with the bottom of the end's
top
dado. Now, insert the seat assembly,
as
shown
in Photo B. Align the seat the
same as
you
did the shelf.
f
Clamp the
rear
seat skirt
(I)
in
place
{t/q" in from the end assemblies'
rear
edges. Using the shank holes
in
the
end
assemblies as
guides,
drill
pilot
holes
into the seat skirts.
Drive in
the screws.
Do not
glue
the rear skirt to the seat.
fiRest
the back assembly
(K/L/IvI)
on
V2Vzx2Vz"
spacers clamped to the
rear
!!$.n*
,ri{*Ei:,{
With one end of the seat assembly resting on a spacer,
flex
the opposite side assembly
just
enough
to
allow
you
to lower the
seat's other end
into its
dado.
WOOD magazine November 2002