Wall Hung Console #6: Getting closer

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Blog entry by captkerk posted 09-22-2009 07:53 PM 1475 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 5: Arc jig, bending form, and more mistakes Part 6 of Wall Hung Console series Part 7: Swine Flu »

I’ve made a little progress over the last couple of days. The curved aprons are done gluing and are all trimmed up. The top has been flush trimmed and sanded again to even up the epoxy filler patches, but a few need to be redone. The three large brackets are cut to size, routed flush with their templates and belt sanded. They need some epoxy filler and they will be ready to receive mortises. I got started on the back board that connects the brackets and mounts the unit to the wall, but I didn’t cut the tenons yet since I haven’t cut the mortises yet.

Today I got the planer sled back out to get another board to 3/4” dimension for the braces. I made another template out of 1/2” MDF to shape the curves and used it to trim up the braces after rough cutting them on the band saw.

routing the braces

I really love the flush trim bit I have to do the pattern work. I’ve tried a really cheap 1/4” shank flush trim bit and then a Bosch 1/2” shank bit, but I’ve had some scary issues with each while routing curves that go across end grain. When I saw the shear cutting flush trim/pattern bit at Rockler I thought I’d try it. It has both top and bottom bearings, is a larger diameter cutter (5/8 or 3/4”) than the Bosch (1/2” cutter) but most importantly the cutter is on an angle to make a shear cut. I’m not sure if it’s the shearing action or if the Rockler bit is just a nicer quality, but that bit performs flawlessly and without any scary grabbing of the stock.

I used that same bit to rout the pattern on even the 3” thick center bracket by taking off the bottom bearing, thus making it a pattern bit, then replacing it to flush cut the remainder. Worked like a charm.

So now almost all my pieces are at least rough cut.

pieces laid out

I still need to cut out the boards that back up the three brackets and then I will have almost nothing but joinery to do. Here’s a little mock up of how it will go together.

mock up

Oh, and the little SNAFU with the biscuit that was revealed when cutting the curve on the top. Well, the repair worked, but it’s not seamless. It just looks like a walnut biscuit on the edge of a walnut top.

biscuit blunder far

biscuit blunder near

So, I am considering a couple of options for hiding my biscuit blunder better. Since there is a little bit of purplish color in the cat’s eye part of the top…

cat's eye

...I’m thinking of using some thin purpleheart and walnut to put an edge band on that would hopefully make the purpleheart look like an inlay. Either that, or I might use a slot cutting bit to rout a groove all around the edge right where the biscuit is and then inlay purpleheart into that slot. I’m still trying to decide and I have some time, since I don’t have any purpleheart, yet.

Right now, I’m doing some more epoxy filling and then I’ll be waiting for some new spiral cutting router bits to arrive before cutting the mortises for the joinery. I may not have much progress before next week, but I’ll post what I can accomplish.

4 comments so far

View CaptainSkully's profile


1600 posts in 3585 days

#1 posted 09-24-2009 05:21 AM

Nice. I’m assuming you’re using walnut for a classic, dark, antique finish. You may not even need to worry about it. I would mock up a piece of scrap with a walnut biscuit and see if your final finish will even show.

-- You can't control the wind, but you can trim your sails

View captkerk's profile


169 posts in 3268 days

#2 posted 09-26-2009 03:23 AM

I’m using walnut on this project because it was free. This project actually came to be when I watched the episode on NYW and showed my wife. She thought it was as neat as I did and said it would look great in our front hall. She also suggested using the walnut that her folks gave me a year before. That walnut was from a tree on their property that they cut down and had a local acquaintance (who has a sawmill) mill it up into lumber. They brought it to me about two years ago and it has been drying in my garage ever since.

Part of why I started on this now is so I could use the remaining walnut on two other, smaller projects. I suggested making drawer and door pulls for our kitchen cabinets out of it but didn’t want to cut into big boards to make small pulls. I would rather try to use smaller scraps to do that. The other reason is so I can make some jewelery cabinets for my daughters for Christmas this year. I wanted to do some walnut and maple cabinets, but again, I wanted to wait until the larger console project was done and use leftovers from that.

View captkerk's profile


169 posts in 3268 days

#3 posted 09-26-2009 03:30 AM

As far as the biscuit repair; I wiped the whole top down with mineral spirits to get an idea what it might look like with a finish on, and the biscuit patch was still noticeable. Maybe it won’t be as noticeable to other people especially after it’s wall-mounted, but I will still see it. I’m actually looking forward to my idea to laminate a 1/4” strip of pupleheart and then a 1/4” strip of walnut to the edge, all the way around. I’m hoping that will not only hide the patch, but give the illusion of an inlay, and bring more attention to the purplish color in the walnut top. I’m also thinking of doing a real inlay of purpleheart on the sides of the end brackets to make the purpleheart additions look more intentional and integral to the design. I won’t be able to do any more work on it until at least Monday when I get back home. Hopefully I’ll be able to make some good progress and come close to fully assembling it before my next trip.

View a1Jim's profile


117120 posts in 3604 days

#4 posted 09-26-2009 04:26 AM

good progress

-- wood crafting & woodworking classes

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