Beth picks up where
she left off last week. The back panel has been glued up. The two raised panels have been
inserted in the rail and stile groove. The top panel is a piece of 1/4" veneered
plywood. It will be added when the other veneered pieces and the glass are added.
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She pops the rabbet
bit back in the router and cuts the top section to receive the veneered panel. All the
veneered panels will be finished separately and put in place at the last step.
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Having done so
many "squaring" of corners last week, Beth takes only a minute or two to square
the corners of this window.
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The cabinet scraper quickly
removes the little trace of glue squeeze out.
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Beth takes a
few minutes at the Delta Bench Random Orbital Sander to sand smooth both sides. This is
where it helps to have the panels cut precisely. The panel surfaces are aligned with the
rail and stile so that this flat sander can smooth both.
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The instructions say to
make sure that both assembled sides and front and back have the same widths. Beth puts
them next to each other and decides that her units are exactly matched.
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The plans call for a tongue
and groove set to be used to join the four sides. I would not have thought of this for
joining the assembly. I think I would have tried using the locking miter bit — that
would have given a joint without a seam showing. Beth and I searched through the plans and
found that the "seam" will be covered by a strip of molding. So this joint
makes sense. It is similar to dadoing the pieces on the table saw, except that the tongue
automatically matches the groove width producing a tight joint.
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Two grooves will be cut into
the length of both sides. The tongue is designed to cut a 1/4" width. The bearing
allows a 3/8" depth of cut — much too much for 1/2" stock. The plans
explain how to swap the pattern bearing to make a 1/4" cut. Rather than to change
bearings, Beth and I decide that we can use the fence to limit this depth.
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She installs the groove
cutter.
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Beth adjusts the fence so
that the cutter depth is 1/4". She has raised the router so that the cutter is
1/8" above the table.
Note, the "sawdust." This is actually white plastic from the fence
insert. Beth found that the zero clearance insert cut for the Junior Raised Panel was
close enough and could be used for this operation with just a small additional routing.
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Beth has clamped a
featherboard in place to keep pressure on the side as it is routed.
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With the grooves cut in the
sides, Beth now installs the other cutter. This one will be adjusted so that it cuts a
tongue that is centered on the 1/2" frame stock.
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After having checked
all the inserts, Beth decides that a new one will have to be cut just for this cutter. She
marks the profile outline.
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Beth cuts the shape at the
bandsaw.
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