I’ll be posting most of the in-depth instructions and photos on my website WoodWorkersWebsite.com but I also wanted to mention a few things here regarding what I’ve learned while making this project. It’s the second indoor project, the first was a clock. I spend most of my time practicing my woodworking skills by making things for my garage.
I designed this project myself which makes it very different from following a plan. I’ve designed almost everything for my shop but all the projects have been with 90 degree corners or a few 45 degree. This project is very different and I often have to figure a few things out as I go along.
The first step I did was to design a pattern from poster board. I had some difficulty determine the angles I needed so I asked for help on this website. People are very helpful here. Drawing provided by member Bentlyj
Miter Saw Angels vs. Table Saw Angles
At first for some reason I thought I was going to cut these angles on a miter saw, so I was trying to determine the angle of the cut. It was at this point I discovered the miter saw is set up for cut to be made from a 90 degree angle. I never thought about this but I’ve never had a problem with it. I read a good article regarding this at http://www.thisiscarpentry.com/2011/07/29/miter-angles-miter-saws/.
After learning about this I realized I was actually going to cutting these on the table saw so all I needed to do was divide the angle in half. I use a Wixey digital angle finder, which I love. I made practice cuts on several Baltic Birch plywood pieces. Once I was satisfied with the angles I cut all my 4 side pieces a ½” wider than what the final dimensions would be. After I cut the desired angle where the 2 side boards meet, I cut the boards to the required length. I added the ½” so I’d have enough room to re-cut the angle if I screwed up.
Problem with the Plywood
After all the angles where cut I noticed I was having a problem with a veneer. It creaked and peeled at the point of the angle. I don’t know that much about plywood but I had purchased an imported ribbon striped mahogany plywood. It was a combination-core, with an MDF layer between the inner plies. I was the only mahogany plywood the plywood place had and I was surprised it was only $54.00.
Since the miter corners looked awful, I stopped the project. I located a different lumber yard and I took a sample of my plywood to them. They explained the problem was caused by the cheap and very thin veneer. He explained that the imported veneer plywood veneer is much thinner than the domestic. He further stated the core is not made as well but the problem I’m having is because the veneer is to thin. He further felt a domestic plywood with the same core would work fine for what I was doing. So the plywood had to be ordered. He stated they don’t carry it in stock because it often gets bumped around in the shop, then it’s worthless. If you saw this lumberyard then you would understand.
For the people that live out here in Southern California I’ll explain that the first place I went to was Far West Plywood. They are mainly a plywood place with a little bit of surfaced woods. The second place I went to was amazing. It’s called Bohnhoff Lumber Co. Although they don’t have a website, they’ve been in business since 1910. They are a full lumber and milling yard. They have a large amount of different types of wood with different types of cut. I always wondered where people could purchase the different type of cuts in wood. When I ordered the plywood he had the option of different cores and different type of cuts. I thought all plywood was cut using the rotary cut method but he explained that there are several different methods.
When I returned home I researched Fine Woodworking Magazine and located an article written in 1996 regarding plywood. The article was good but it still lacked some information. http://www.finewoodworking.com/FWNPDF/011117038.pdf
When I was at Far West Plywood I purchased some African Mahogany because they didn’t have any Honduras or Genuine Mahogany. Once I got home I cut it and tried to match the pieces for the top. The wood I purchased was more of a mixed cut. I went to another lumberyard and purchased some Honduras Mahogany but when I got it home I like the way the African Mahogany matched the plywood. While I was at Bohnhoff Lumberyard I explained to the man about the problem with trying to match the table top wood to glue up. He explained that they purchased some 6/4 African Mahogany that is quartersawn so the wood will match easily. Actually it’s the first time I’ve seen wood in something other than 4/4 or 8/4. I purchase a 6/4 piece of rough lumber that was approximately 11-3/4” wide by 14’ long. This is the first time I’ve purchased a large piece of completely rough lumber. They would have milled it but I wanted to try to do it myself.
I’m waiting until my new plywood arrives. He stated it would only take a day or two.
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