In his great series of woodworking shows there was one thing David did over and over that got some gentle teasing around the web. Can you tell which photo depicts this?
Before I cut the mortises for the stiles and top/bottom rails I have to first make up the arch assembly. Through Sketchup I calculated that two boards cut on 12 degree angles would work. I’m still looking for a calculator, table, or formula that allows some what-if-ing of various dimensions to calculate various sized arched segments. Until then I’ll have to stick with Sketchup and experimenting with best fits (see Blog 1 in this series).
First I had to laminate some 2x stock which is really 1 1/2” with some 1x stock which is about 3/4” to make up some 2” thick boards. I cut the two pieces that make the arch segment a little oversize and clamped them together to mark the mortises. I used a 3/8” bit and set the distance from the guide fence using a 7/16” drill bit. I’ve learned the fastest and most accurate method is to cut the mortises then rip or resaw some stock then round the edges on the routher table to fit the mortise. I also use some chisels to clean out and smooth the walls of each mortise. Next will be the plumb cuts.
-- tim hill www.newcalshop.com