Arts and Crafts Entertainment Center / Sideboard #2: Pattern Routing Curves, Mortiser Mod, Side Panel Glueup

For those who are just joining, this is what I am building.

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Time to pattern rout the lower side rails with an arched shape.

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I made an oversized base with toggle clamps to hold my workpiece in place. After bandsawing the rail to rough shape I clamp it in the jig, and zip it to shape.

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Arch complete.

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I stained the front side of the floating panels, and built the side assemblies. I installed some 1/4” foam weatherstripping in the groove to help center the floating panel. I had an issue with the clamps near the rear rabbet. Initially the clamps pulled the leg out of square.

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I solved the problem by using small blocks to direct the clamping pressure in-line with the joint.

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Then I cut tenons on the long lower rail. I clamped them tight to the legs so I could pre-cut mortises for the walnut pegs. This step must be completed before the long rail is glued in place, otherwise the mortiser can’t make the cut.

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I made a modification to my mortiser to eliminate bit binding. My hold-down was not square to the workpiece so I added unequal thickness shims. This does two things… 1) it lets the hold-down sit flat on the workpiece to prevent racking and bit binding, and 2) it prevents marring the workpiece because the shims are made from fir.

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Then I made a dado jig.

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It features a start block so the router won’t ruin the jig, and a removable stop block. This will be used to rout stopped dados in the sides.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush