I called it a saddle, but it is more like a pommel as in gymnastics’ pommel horse. Whatever. In order to veneer the inside of the curved drawer fronts, and ensure adequate clamping pressure at all points, I had to make a perfectly matching curved form or block to press against. While I had never done this before, I relied on memory of several of David Marks’ Woodworks TV shows and videos where he described the process and key elements. The goal is to make the block undersized enough to allow for a layer of 1/4” thick cork, which I was able to find wider sheets at a hobby store, and cover that with a layer of packing tape so the glue doesn’t stick. And lastly, to use a glue that hardens upon curing. I think David mixes his own, but for this application I used the TightbondOne premixed and it worked great.
I made the pommel/saddle the same was as the drawer fronts shown in the previous chapters. I made a pattern, rough cut the shapes, and trimmed them to the pattern on the router table. I glued them together making sure they were perfectly aligned and glued a layer of cork sheet with the packing tape on last. You may be wondering why I didn’t use the vacuum press? Well I did, but I found using the screw press and side clamps worked best. Because of the steep angle of the sides the vacuum press didn’t quite supply the pressure needed for a real tight bond. I cut clamping wedges to the appropriate angle which allowed for a clamp to provide the 90 degree pressure and it worked great.
So after the drawer fronts set I did some light hand sanding and cut them to width on the bandsaw which I had set up using one of David Marks videos as a guide. The result speaks for itself. So without further explanation, justification, or defense (I have none), I hereby present The Inside Story, Veneering the Inside Curve. Enjoy.
Whew! Just four more drawers to go! So I’m guessing you may have questions? What is the pink blanket for? And the moving pad? And where did you get that real cool, innovative screw press? Well I’ve got answers. An electric blanket. An insulating pad to hold in the heat. I invented it. And it was a Daily Top 3 too!
Next time we’ll veneer the outside curve, or the drawer fronts. Maybe call it The Outside Story?
-- tim hill www.newcalshop.com