25-05-2012, 09:29 PM
Hi,
Yesterday I made good progress much to my relief. The top and under frame needed to be brought together and biscuit joints were used throughout. In order to prevent ending up with a lot of scrap oak and Formica this job was done in two parts. The first part was to add the two end panels; two drawer dividers and the rear cross member to the underside of the desk top using biscuits.
It looks very easy to simply attach the lower oak frame using biscuits but in fact it is very difficult unless this type of work is carried out frequently. It is extremely easy to cut biscuit slots in the wrong position so I had to devise a fool proof way of adding the slots. For butt joints two pencil marks are added in the joint centre position and with the pencil marks uppermost the joint is very easily cut. Now add two pencil marks for a joint where an edge is to be joined to a face and not just one joint but in this case twelve of them.
Method of aligning joint and a difficult joint made easy.
The sole of the biscuit joiner needs to be positioned so that both slots align perfectly in both directions; lengthwise is easy but across the biscuit can prove difficult and at times frustrating to get right. Once the pencil marks are added and the parts separated things quickly get out of hand and in a pair of big sections like these there is a lot of room for error. Some slots were in line with members but others fell across members.
Biscuit slots cut.
Gluing the members to the underside of the desk top worked out very well indeed. I placed the top face side down onto the MDF table leaving the members standing upright; the lower oak frame was then very accurately positioned ensured this too was placed face down and all the upright members were drawn around using a pencil leaving the shape and before separating all the joint positions were clearly marked. A lot of time was spent doing this as a single slot in the wrong place would spell disaster. On the upright members a strip of wide MDF was attached at each joint using quick release clamps; this ensured the joint was truly straight but it was difficult at first to keep alignment because activating the joiner switch was awkward and once power was applied the joiner gave a strong kick as it isn't soft start. With a little practice I soon grasped what was wanted and with the MDF guide in place could cut two slots very quickly by switching the joiner on before locating it; the sawdust covered me but I carried on.
The top side of the oak frame was much easier as a wooden straight-edge could be aligned and these slots were cut at speed. Not being brave enough to add glue a dry test fit was important and it came as a total relief to see the two parts come together perfectly with every biscuit perfectly aligned and where it should be. Glue up followed. Plenty of water based woodworking adhesive was added to the slots and brushed well in and before pushing the biscuit into the slot the biscuit was also coated with glue.
Biscuits added dry for test fit.
Before assembly a lot of time was spent sanding. At first my Bosch random orbit sander was tried and this was a rather expensive machine when bought years ago but is now just a load of junk; it throws sanding pads off with ease rendering it useless due to the hook and loop pad attachment; I've no intention of spending around £16 to buy a new base for the sander only for this to fail at some future time; when I get some spare time I'll try to add a new home made base to accept glued pads.
I resorted to using my old but trusty Bosch standard orbit sander with the abrasive sheet mechanically clamped in place. Unfortunately this causes as much work a it saves because it leaves deep swirl marks which are a real pain to hand sand out. I did so much hand sanding yesterday that I suffered a lot of pain in both arms and shoulders last night in bed.
Underside of top and new drawer openings.
I'm pleased the two sections went together so well and next job is to make the three drawers; this top section will be completed and finished before work starts on the two bottom sections. The Formica panel still retains its protective film which will remain in place until finish is applied to the oak frame.
New desk top still with protective film on Formica.
Kind regards, Col.
Yesterday I made good progress much to my relief. The top and under frame needed to be brought together and biscuit joints were used throughout. In order to prevent ending up with a lot of scrap oak and Formica this job was done in two parts. The first part was to add the two end panels; two drawer dividers and the rear cross member to the underside of the desk top using biscuits.
It looks very easy to simply attach the lower oak frame using biscuits but in fact it is very difficult unless this type of work is carried out frequently. It is extremely easy to cut biscuit slots in the wrong position so I had to devise a fool proof way of adding the slots. For butt joints two pencil marks are added in the joint centre position and with the pencil marks uppermost the joint is very easily cut. Now add two pencil marks for a joint where an edge is to be joined to a face and not just one joint but in this case twelve of them.
Method of aligning joint and a difficult joint made easy.
The sole of the biscuit joiner needs to be positioned so that both slots align perfectly in both directions; lengthwise is easy but across the biscuit can prove difficult and at times frustrating to get right. Once the pencil marks are added and the parts separated things quickly get out of hand and in a pair of big sections like these there is a lot of room for error. Some slots were in line with members but others fell across members.
Biscuit slots cut.
Gluing the members to the underside of the desk top worked out very well indeed. I placed the top face side down onto the MDF table leaving the members standing upright; the lower oak frame was then very accurately positioned ensured this too was placed face down and all the upright members were drawn around using a pencil leaving the shape and before separating all the joint positions were clearly marked. A lot of time was spent doing this as a single slot in the wrong place would spell disaster. On the upright members a strip of wide MDF was attached at each joint using quick release clamps; this ensured the joint was truly straight but it was difficult at first to keep alignment because activating the joiner switch was awkward and once power was applied the joiner gave a strong kick as it isn't soft start. With a little practice I soon grasped what was wanted and with the MDF guide in place could cut two slots very quickly by switching the joiner on before locating it; the sawdust covered me but I carried on.
The top side of the oak frame was much easier as a wooden straight-edge could be aligned and these slots were cut at speed. Not being brave enough to add glue a dry test fit was important and it came as a total relief to see the two parts come together perfectly with every biscuit perfectly aligned and where it should be. Glue up followed. Plenty of water based woodworking adhesive was added to the slots and brushed well in and before pushing the biscuit into the slot the biscuit was also coated with glue.
Biscuits added dry for test fit.
Before assembly a lot of time was spent sanding. At first my Bosch random orbit sander was tried and this was a rather expensive machine when bought years ago but is now just a load of junk; it throws sanding pads off with ease rendering it useless due to the hook and loop pad attachment; I've no intention of spending around £16 to buy a new base for the sander only for this to fail at some future time; when I get some spare time I'll try to add a new home made base to accept glued pads.
I resorted to using my old but trusty Bosch standard orbit sander with the abrasive sheet mechanically clamped in place. Unfortunately this causes as much work a it saves because it leaves deep swirl marks which are a real pain to hand sand out. I did so much hand sanding yesterday that I suffered a lot of pain in both arms and shoulders last night in bed.
Underside of top and new drawer openings.
I'm pleased the two sections went together so well and next job is to make the three drawers; this top section will be completed and finished before work starts on the two bottom sections. The Formica panel still retains its protective film which will remain in place until finish is applied to the oak frame.
New desk top still with protective film on Formica.
Kind regards, Col.
Happiness is a wreck of a cabinet to restore.
