I am starting a new project. Its an Arts & Craft sideboard that was a project in Fine Woodworking back in 2015 done by Gregory Paolini.
At first I had opened to the group here a conversation about changing some of the dimensions and features. But after looking at the plans closer I am staying with the original design. The picture is somewhat deceptive in that it makes this piece look like it is shorter in length then it really is but it is over 50 inches long and I think the deception comes from the fact that the height of the of the sideboard's flat surface is 39 inches. A normal china cabinet is about 32-33 inches.
The original piece in the magazine was done in QSWO, a traditional choice for Arts & Crafts but I am going to use Cherry. So this is the pile I brought home from the lumber yard. The project uses around 70 board feet but my stack is 120 board feet. I went way over because I wanted to be pretty picky with all the frame work pieces. I wanted all of the legs, stiles, rails and things like that to have pretty straight grain and then the door panels, drawer fronts and side panels will maybe have a little more character.
So the first thing I did was pick out and cut all my frame work pieces and I ended up with this stack.
After they sat for a couple of days, I went back through and bundled all the pieces with their corresponding parts to make sure I hadn't missed any thing.
Next up was milling all the leg pieces and gluing them up. The legs are 2 1/4 inch square and I am going to get this by gluing 3, 3/4 thick X 2 inch wide lengths together to give me 2 1/4 in one direction and then I will glue a 1/8 inch X 2 1/4 inch wide veneer on each side to hide the lamination and and give me my 2 1/4 inch dimension on the other sides and with the help of a small chamfer the appearance of solid 2 1/4 inch thick legs.
In the clamps for the first phase of the glue up.
On the next part, when I glued the veneers on I wanted about an 1/8 inch over hang on each edge so to keep things oriented I stood the clamps up. Jet clamps are heavy but for something like this they really shine because they can be stood up and the jaws stay open.
And the first two in the clamps.
When I added the other two legs to the stack I started to notice a problem. The veneer that was on the very bottom was starting to open up gaps. I don't know what it is but it seems that when I am in the midst of a glue up my common sense leaves the building. So I just started throwing clamps at the situation, I got the problem fixed but ended up with what you see below. If I had thought about this for even 30 second I would have come up with the better fix which would have been to take everything out of the clamps and put a thicker piece of stock on the bottom to act as a caul and the clamp rack would still be full.
That was the first glitch. The second on I didn't see until I got things out of the clamps this morning. And again if I hadn't been in a mild panic mode yesterday afternoon doing battle with my gap problem, I might have discovered this in time to fix it. One of my veneers slide out of alignment. It slid from being okay at one end but way off the mark at the other. I cleaned up and flushed up the rest of the leg then tackled the problem. I put a blade form my dado stack on the saw and then put the clean surface marked in the picture below (this picture is before the dado was cut) down on the table saw and cut a dado out of the leg that was 1/2 inch high and 1/8 inch deep. This cleaned up the remaining glue and gave me an even surface to work with. I then found a scrap that was close in grain but more importantly a color match and glued it into place with the help of lots of blue 3M clamps.
And this is my cleaned up result, the fix is on the right side and you can see in the second picture the end of the piece I put in just to give you an idea of where the glue seem is.