031308_bonus-download_scroll-saw.pdf
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Pobierz
W
EEKEND
P
ROJECT
F
RETWORK
P
ICTURE
F
RAME
With a scroll saw and
a few extra hours, you
can turn a plain frame
into this elegant one.
O
ccasionally, I enjoy sitting down
and cutting fretwork patterns with
my scroll saw. The change in pace is
a nice break from my typical wood-
working routine.
But like any time I spend in the
shop, I want to end up with some-
thing I can be proud of. Something
that belongs on a mantle, a night
stand, or in a grandchild’s bedroom.
This fretwork frame is just the kind
of project I enjoy. It doesn’t take much
time. Plus, it turns a plain frame into
an attractive, heirloom project.
PANELS
. The best way to begin is to
cut two identical panels: one for the
fretwork and another to back the
photo, see the drawing below. I
designed them to hold 3x5 photos.
But after taking a few measurements,
I realized that 3x5 photos aren’t exact-
ly 3" by 5". So if you have a particu-
lar picture you want to put in this
frame, cut the panels to match your
photo. (My panels were 3
1
/
2
" x 4
3
/
4
".)
Once the panels are cut to size, it's
time to cut the fretwork pattern in
one of the panels. So set the other
a.
NOTE:
Frames
sized to hold
’3 x 5’ photo
FIRST:
Cut frame
blanks
to size
4
!/4"
!/2"
4
!/4"
Rip
fence
!/2"
x
brass hinge
#/4"
! !/16"
b.
SECOND:
Round over
edges of
each blank
R
o
uter
fence
5
!/2"
5
!/2"
!/8"
round-over bit
c.
THIRD:
Cut groove
to hold panel
PANELS
(
!/8"
x 3- 4)
!/2"
#/4"
!/8"
!/8"
Deep
groove
Center
groove
on blank
!/8"
#4 X Fh
woodscrew
!/2"
FRAME PIECES
(
NOTE:
For more
on cutting fretwork,
see page 26
!/2"
x)
!/2"
24
Woodsmith
No. 103
panel aside, and photocopy one of the
patterns shown below. For more on
cutting fretwork patterns, see the arti-
cle on page 26.
FRAMES
. When the fretwork is com-
plete, the panels are ready for the
frame pieces. I started with extra-
long
1
/
2
" x
1
/
2
" blanks, see detail ‘a’ on
the previous page. Just be sure to
make a few extra. You’ll need them
when setting up the cuts.
I wanted the frames to be simple,
so the attention would be on the
photo and the fretwork. So for deco-
ration, all I did was round over the
edges of the blanks, see detail ‘b’.
Next, to hold the panels, a centered
groove is cut in each piece, see detail
‘c’. This groove should be just wide
enough to hold the panels. With my
1
/
8
" thick panels, a single pass on the
table saw with a combination blade
was all that was needed.
ASSEMBLY
. Now the frame pieces are
ready to be mitered to finished length
and then assembled around the pan-
els. With the frame for the fretwork,
this is simply a matter of gluing and
clamping the frame around the panel.
But the frame for the photo has to
be assembled a little differently. Here,
I glued up one corner at a time until
three of the pieces were together.
Then the bottom piece is simply
screwed in place, see Fig. 1.
At this point, the panel that backs
the photo fits too snug in the grooves
to include the photo and an acetate
cover. So I sanded the panel just
enough to reduce its thickness until
ever ything fit into the grooves.
FINISH
. Finally, I finished the frames
with an oil finish. Then I stacked
them together and joined them with
a pair of brass hinges, see Fig. 2.
❑
Use clamps to hold frame
while drilling
pilot holes
1
2
a.
Photo
Acetate
#2 x
Brass
screw
#/8"
#4 x Fh
woodscrew
!/2"
!/2"
Stack frames and
attach hinges
Full-size Patterns
No. 103
Woodsmith
25
Night Light
Light up the night with four interchangeable patterns featuring enchanting scenes that are sure to
please your child. All it takes to build it is a scroll saw, a small light bulb, and a weekend in the shop.
Night Light
S
ome projects get their charm from
the wood that’s missing. This Night
Light is one of those projects. It’s
just a box with the sides, top, and bottom
made from solid wood. What makes it
interesting is the interchangeable front
panel that screens the light shining from
a small bulb inside.
I designed this Night Light with four
of these scroll-sawn hardwood panels.
Then, depending on your mood or the
season, you can slide one in front of the
light, and store the others in a compart-
ment in the back of the box.
PANEL DESIGNS.
be easy to come up with hundreds of dif-
ferent ideas for your own panels. I’ve
included four examples for the panels in
my Night Light. Each has a magical
quality that will look nice in a child’s bed-
room or sitting on a hallway table or
stand. (You can find the patterns in the
Designer’s Notebook on page 82.)
WOOD.
light bulb fixture, along with a full-size
drawing of each of the four patterns (and
a piece of felt cloth for the bottom) is
available from
Woodsmith Project
Supplies.
(See Sources on page 126.)
THIN STOCK.
Except for the sides, each
piece in this project is made from wood
that’s
1
/
2
" thick or less. Finished stock
this thin can be found, but it may cost a
bit more. A good alternative is to resaw
the stock from thicker boards. (For more
on this, go to the Technique on page 65.)
SCROLL SAWING.
I used cherr y for all the parts
of the Night Light. The color and warmth
of cherr y enhance the glow cast by the
light. And because cherr y is close-
grained, it cuts well on a scroll saw.
SUPPLIES.
And to learn the
secret to making the most of your scroll
saw projects, I suggest you check out
the Technique article on page 86.
The light fixture is a
Christmas-tree-size (4-watt) bulb that
clips tightly into the base of the box. This
If you’re artistic (or
have clip art on your computer), it would
78
SCROLL SAWN
EXPLODED VIEW
OVERALL DIMENSIONS:
6W x 5
1
/
4
D x 9H
C
LID
BACK
PANEL
A
D
LID BLOCK
DIVIDER
PANEL
A
INTERCHANGEABLE
PANEL
A
SIDE
B
B
SIDE
LIGHT BOARD
E
LIGHT FIXTURE
BASE
C
CUTTING DIAGRAM
#/4
MATERIALS LIST
x
5
!/2
- 36 (
Two Boards @ 1.2 Bd. Ft. Each
)
WOOD
A
Panels (6)
D
1
/
4
x 4
3
/
4
- 8
B
Sides (2)
3
/
4
x 4
3
/
4
- 8
A
A
A
E
1
/
2
x 5
1
/
4
- 6
C
Base/Lid (2)
D
Lid Block (1)
1
/
2
x 2 - 4
1
/
8
x 2 - 4
E
Light Board (1)
#/4
x
5- 6
!/2
(1.2 Bd. Ft.)
HARDWARE SUPPLIES
(4) No. 6 x 1" Fh woodscrews
(1) Felt cloth (6" x 6")
(1) Night light socket switch w/ cord
(1) 4-watt frosted bulb
B
B
C
C
NIGHT LIGHT
79
RESAWN PANELS
1
2
SECOND:
POSITION FENCE
SLIGHTLY MORE THAN
" FROM BLAD
E
MAKE TWO
PASSES,
FLIPPING
WORKPIECE
END FOR END
BETWEEN
PASSES
!/4
PANEL BLANK
Start building the Night Light by cutting
the six panel blanks — four for the inter-
changeable panels (A), plus one divider
panel (A), and one back panel (A). The
Night Light box is built around these.
PANEL BLANK.
A
PANEL
(CUT SIX PIECES
" THICK)
(#/4
"
4
-THICK STOCK -
x
#/4
"
26")
!/4
8
To make these six
1
/
4
"-
thick panels, first cut a piece of
3
/
4
"-thick
stock to final width (4
3
/
4
") and rough
length (26")
(Fig. 1)
.
RESAW PANELS.
4#/4
FIRST:
!/2
SET RIP BLADE
TO CUT 2
"
HIGH
Then resaw this into
two panels that are each slightly thicker
than
1
/
4
". I used the table saw and made
two passes with a sharp blade
(Fig. 1)
.
(For more on this procedure, see the
Technique article on page 65.) You could
also use a band saw or thickness planer
to reduce the stock to
1
/
4
".
Now, sand or plane the saw marks
from all the panels so they’re all
1
/
4
" thick.
Then cross-cut both blanks to produce six
8"-long panels
(Fig. 2)
.
Note:
You could use plywood, but the
plies will show on the finished panels.
PATTERNS.
I used the table saw with a rip blade to
form all the grooves. But before cutting
the grooves in the blank, cut a test piece
the same size as the blank to check the
width and position of each groove.
The first grooves to cut are the two
outside ones
(Fig. 3)
. To do this, I set
the fence
1
/
4
" from the inside edge of the
blade, and raise it
3
/
8
" above the table.
Now you can make one pass to cut a
kerf in the test piece to form the outside
edge of the groove. Then turn the piece
end for end and cut a kerf near the other
edge. When you’re satisfied with the kerf
depth and its distance from the edge, cut
kerfs on both edges of the actual work-
piece, following the same procedure.
Next you can reposition the fence and
make a second pass on the test piece, so
that the
1
/
4
" panels fit snugly in the
grooves in the test piece. Then make the
cuts on the actual workpiece to complete
the two outside grooves.
You’ll form the groove for the divider
panel in the same way. This groove
should be located 2" from the back edge
of the box sides
(Fig. 3)
.
Next, I cut a 1"-
wide storage chamber by making a series
of passes through the rip blade
(Fig. 3)
.
To make the sides appear thinner than
they actually are, trim the front and back
edges down to
1
/
2
" thick
(Fig. 4)
. To do
this, set the table saw blade
1
/
2
" from the
fence and
3
/
8
" high
(Fig. 5)
.
BULLNOSE PROFILE.
STORAGE CHAMBER.
After trimming the
outside edges of the sides, rout a bull-
nose profile on them with a
3
/
8
" roundover
bit in a router table. To do this, first raise
the bit
1
/
4
" high and round over the out-
side edges (grooved face
up
)
(Fig. 6)
.
Then raise the roundover bit
1
/
2
" high, flip
the workpiece over, and round over the
inside edges (grooves
down
)
(Fig. 7)
.
PRE-ASSEMBLY.
Now use the patterns in
the Designer’s Notebook on page 82 to
lay out the designs and cut them out.
SIDES
Now cut the side piece
into two 8"-long sections
(Fig. 3)
. Then
glue the back and divider panels in place
between the two sides.
After resawing and cutting the six panels
to size, the next step is to make the
grooved sides of the box.
SIDE BLANK.
The two sides (B) start
out as one blank of
3
/
4
"-thick stock. Cut
the blank to finished width (4
3
/
4
") and
rough length (16
1
/
2
")
(Fig. 3)
.
PANEL GROOVES.
BASE & LID
Begin making the base and lid of the
Night Light by cutting an over-size blank
to final width (5
1
/
4
") and rough length
Next, cut three
1
/
4
"-
wide grooves for the panels to slide into.
3
4
5
B
FIRST:
CUT TWO
OUTSIDE GROOVES
SLIDE SIDE
PIECE AGAINST
FENCE TO
TRIM EDGES
SIDE
RIP
FENCE
B
B
SECOND:
CUT
DIVIDER GROOVE
B
SIDE
8
!/2
THIRD:
CUT STORAGE
CHAMBER
BACK
EDGE
SET BLADE
HIGH
#/8"
B
SIDE
TRIM FRONT
AND BACK EDGES
OF SIDE PIECES
TO
!/2
NOTE:
USE TEST PIECE
TO CHECK CUTS
#/4
!/2"
THICK
8
ALL GROOVES
ARE
6
7
ROUTER TABLE
FENCE
4#/4
#/8
" DEEP
!/4
!/4
!/4
ROUND OVER
OUTSIDE EDGE
ROUND OVER
INSIDE EDGE
#/8"
RO
UNDOVER
BIT
2
1
B
B
!/2
!/4
80
SCROLL SAWN
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