Decided to make lamps for Christmas for my mother in law. Found a very cool book on japanese lamps so decided to take a crack at it:
Key Steps in process:
1. Prep plans and Mill stock (not shown)
2. Cut and Route legs
3. Cut, Route and Rip kumiko (rails and styles)
4. Cut and route top
5. Test fit sides
6. Glue up side panels, legs and lid
7. Add light socket
8. Light up!
Step 1 – Mill Stock
Started out with book, shoiji paper and reclaimed wood from a prior project.
Instructions in book are light on details so I made a more detailed parts list.
Step 2 – Form legs
Cut 1×1” legs to width on table saw
Cut to length on RAS
Route dados to hold frames on inside of legs
Step 3 – Form Kumiko
I route the dados in one large piece and rip to size as it is easier.
Route kumiko that form the inner frame middle stretcher
Route kumiko that form the inner frame sides
Rip the kumiko to width
And I end up with a stack of parts ready to build
Step 4 – Form the top
Miter cut the top piece
Use an angled stop to cut pieces to consistent size
Test fit the miter and it looks good (it is not of course, but we will address later)
Cut the rest of my sides
Use biscuit cutter and holding jig to add support to miter joint
Test all four sides and find out how ugly a 0.3 deg miss on each miter looks – ugly.
Use a shooting board to clean up miters
Glue up top with no ugly gap
Use table edge bit to route a gradual curve around top.
Use 1/8” round over bit to soften inner edges
Step 5 – Test fit the assembly
I discovered during this phase that it pays to make lots of extra kumiko … they are fragile and easily break during fitting.
Use block plane to make final fit
Stack of unglued sides
Route the cross braces
Test entire assembly without glue
Step 6 – Glue up
Start with sequenced group of parts
Dab a little glue at each joint and friction fit
Clamp frame to table with caul to eliminate twist after checking for square assembly.
Once try, you can roll out the rice paper.
The cut and glue using white glue. Once glue is dry, you mist the paper with water and it gets as tight as a drum. Make sure you have even glue coverage on paper or it will separate during this step.
Clamp assemblies together and let dry
The clamps legs in place and let dry
In order to join top, I used dowels. First I created a template.
Used template to drill dowels for legs
Used same template for top
Glue in dowels
Glue on top
Step 7 – Create bulb holder
Using left over scrap, I cut rabbets on the edges and then used forstner bit to drill out a 1” hole. I slipped a pre assembled mini candelabra lamp kit into the hole and screwed holder into lamp base.
Step 8 – Light Up.
I sanded assembly to 220 grit and finished using wax. Then I lit them up and enjoyed.
Next time I try this, I going to try entirely with hand tools.
-- Shawn, I ask in order to learn