TL WOODWORKS: INTERMEDIATE 1996-1997 CHIPPENDALE MIRROR PROJECT Built fom solid maliogaay and ribbon stripe plywood his framed mirror is a beautiful wall pece thai fashionable a wells functional. ‘Stained and finished propery it captures the Chippendale tye renowned for ts classic charm, I's an excellent project choise for intermediate woodworking students because it requires them tobe accurate as well as patient: two qualities every polished woodworker ‘ust posses, ‘This project presents the opportunity not only to practice and hone basie woodworking skis, bu also to learn and master such intermediate ‘woodworking skill as measuring, laying out stock, creating and transfering a design template, cutting wih a scroll saw using stationary and portable power tools, creating and using a jig, and achieving a professional-looking Qnish. TOOLS REQUIRED: Combination square — Assorted files (round andat) Hammer — Dill press Malle: ~ Safe gases Block plane ~ Assorted bit MATERIALS REQUIRE! See Shopping and Cutting Lists FINISHING PRODUCTS: Pencil ~ Assorted clamps (,handscrew, etc) ~ Compass and/or French cane Table saw with dado headset — Ruler (agai or tape) = Jointer ~ Sanders (stationary bel, random orbit, pad) = Router (12" straight cuter bi) Finish Recommended For This Project Miscellaneous — MINWAX@ POLYSHADES® One-Step Siain & Polyurethane — MINWAX fine finishing brushes = Clean rags Alternate finish choices (Choose one} Fine steal woo! = MINWAX@ WOOD FINISI™" = Pant thier, i quired = MINWAK® Wipe-On Poy = Waterfile metal container with cover = MINWAK™ Wood Glue = MINWAX™ Sanding Blocks BEFORE YOU BEGIN 11s imperative that you select only defect-fre stock for this projec, since there is very lite wood used andthe handsome tim shape ‘will draw atenton to ise your local lumberyard doesnot stock such materials, you can order it from one ofthe well-established inall order houses that suppy woodworking materials. Discus ths ‘option with your instructor. PROCEDURE: 1. Frame: Layout, Cutting, Assembly BUILDER'S TIP: Whenever you build a piece of furmiture using exotic woods, it isrecommended that all individual ‘parts be cut and installed so the surface grains “run” in the ‘same direction, By doing so, you'll maintain the structural and esthetic integrity of the piece once it's assembled. This is done in this project, for example, to acbieve the visual impression tbat the scrolivork is cut from a single piece of wood. 1, Cutout four frame members (parts FE and Fee diagram for dimensions). The easiest way to do this st rip one 4 length of stock to size. Sand the pieces smooth using 100-grt sandpaper, then plough the rabbets(1/4" deep x 3/8” wide) that will receive the mirror. 2. Trim four frame parts to exact length, with 45 degree miter cats on each end. 3. Construct the jg for citing the four spline grooves. Note: Make several test cuts using scrap wood to ensure accuracy of cus 4, When satisfied wih jig, cut spine grooves on each end of frame pans E and F Page 1 of 6—‘PROJECT 2 CONTINUED - WOODWORKS: INTERMEDIATE - CHIPPENDALE MIROR 5. Using the table saw and éado head with 1/8" blade, reposition the rip fence and carefully cut the 1/4” x 1/4” grooves in pari E and F (see diagram), which wil receive the scrolled pieces (Pats A,B, C and). 6. Lay out and cut four splines (see diagram for dimensions). 7. Test assemble frame (witout glue) to check for fit and square. 8. When satisted, assemble frame using small amount of gle. Hold pieces in place with clamps positioned so that they wil not interfere with the spine installation, 9. Apply small amount of glue to all surfaces ofthe frst spine and inser into first groore. Genty tp spline into place uni the shaped inside corner i Hush with inside edge of rabbets, Carefully wipe away any excess glue, 10, Repeat for three remaining splines 11, Set the clamped frame assembly aside to dry overnight IL Scrollwork Pieces: Layout and Cutting 1. Create paper patterns forthe four scroll pieces (pars A,B, Cy see diagrams for desgn, sale and dimensions). ‘Transfer ‘alters to heavy eardbeard or 1/8" phywood to create the ‘design templates. When satisfied, carefully cut out templates ing a scroll saw or sake saw equipped with a finetooth ‘wood cuiting blade. Remember to cut the bottom comers a 45 degrees where pieces wil be inserted ito frame grooves. BUILDER'S TIP: Though cardboard can be easy to work with, ‘most woodworkers prefer to make templates from thin ‘Plywood or hardboard because files and sandpaper can be ‘used on edges to obtain perfect shape. And, they bave a Tonger sbel fe if you plan to make the pattern part of a ‘permanent template collection. 2, Using the templates, transfer the scroll shapes tothe stock ‘wood. Using the scroll aw and afine-tooth blade, cut out pieces so all wood grain runs vertically. Reminder: You will need to cut two pieces each of parts C «and D, Also, te template used for parts A and B only represent one-balf ofeach piece, so to create the complete ‘pieces, youl need to trace the template, fip it and trace ‘again. 3. Carefully sand all edges smooth, taking care not to change their shape. Next, sand surfaces smooth using the pad sander and 150-grit paper. Remember to sand wit the gran to avoid ‘ross grain scratches, IML Frame and Serollwork Assembly 1, Retrieve frame. Trim any exposed spline edges Nush with frame. 2, Tes fit scrolled parts, making sure the frame's cormer joints are tighly closed. Make final adjustments to the sero if necessary, sing a file ard sandpaper. 3. When satisfied with it, aoply a small amount of glu to all mating surfaces and reassemble. Ft piece with rubberbands to hold scroll pars in place while glue dies. 4, Set assembly aside to dry overnight. 1. Mirror Retainer Panel 1. Lay out and cut the mirror retaining panel (see diagram for dimensions). Make certain you allow for the eight “ears” ‘which wil hold the panel and mirror in place 2. Bore screw holes through the retaining pane’ ears, Countersink screw hoes for serew heads. 3, Rerieveframe/srollwork assembly and remove rubber. bands. Position retainer pane! on frame assembly's back side and hold in place. Using a pencil, carefully trace the position ofthe panel’ ears on the frame. Remove retainer panel 4, Use router chucked with a 1/2" diameter straight cutter to rout the eight mortises in the frame that will receive the panel cars, Prepare the router by sting the straight cuter soit projects a mere 1/8" below the shoe, Then, rst the router shoe onthe frame (without cuter touching wood) and align the enter with lines forthe frst mortise. Star the router and slowly feed the cutter into the wood, using the pencil lines as your guide for where to stop. ‘BUILDER'S TIP: Make sure the frame is securely clamped to the workhench so that both bands are free to control the router and so thatthe piece will not shift during this critical step. 5. Repeat for seven remaining mortises 6. Test panel for fit, Make any necessary adustnents 10 mortises and/or eas using a chisel or razor knife and sandpaper. V.Final Assembly 1. Lay frame/scrollwork assembly Bat, back side up. 2. Insert minror. Postion mirror retainer panel and secure with eight no. 6 athead screws 3, Install screw eyes and picture wire. VI. Staining and Finishing BUILDER'S TIP: When it comes to staining ard finishing, you can work with a stain-and-finish-in-one product, such ‘as MINWAK® POLYSHADES®, or use the traditional two-step me- ‘hod (MINWAX® WOOD FINISH™ and MINWAX® Wipe-On Poly). Stain and Finish in One: 1. Sand surfaces smooth. Wipe with a tack cloth to remove dust 2, Using quick release masking tape, carefully mask off the perimeter ofthe mirror so it wil not be inadvertently affected by stain, 3. If using a soft wood such as pine, apply MINWAX@ Pre-Stain Wood Conditioner according to label instructions. Wait 10 to 15 minutes, and wipe away excess using a clean, lint-free rag. 4. Within 2 hours apply MINWAX® POLYSHADES® color of your choice using a natural bristle brush. Sir well before and ‘ecasionally during use, Two coats are recommended for ‘maximum beauty and protection. Brush on a thin, even coat inthe direction ofthe rain. Be sure to maintain a wet edge”. Let dry 8 hours or more, then rub surface with fine — Page 2 of 6—"PROJECT 2 CONTINUED - WOODWORKS: INTERMEDIATE - CHIPPENDALE MIRROR steel wool (grade 000 and finer). Remove all dust Brush on ‘a second thin coat. You may apply more than 2 coats if you ‘want to deepen the color 5. allow piece to set for a east 24 hours. ‘Two-Step Method: 1. Sand surfaces smooth. Wipe with a tack cloth to remove dus. 2. Using quick release masking tape, carfilly mask off the perimeter ofthe mirror o it will not be inadvertently affected by stain 3. If using a soft wood such as pine apply MINWAX® Pre-Stain Wood Conditioner according to label instructions. Wait 10 to 15 minutes, and wipe away excess using a dean, lint-free rag. 4, Within two hours, apply the MINWAK® WOOD FINISH™ of your choice to all surfaces (even back) using @ clean brush and with-the-grain strokes. Remember to stir the stain wel ‘Allow stain to penetrate for 5 to 15 minutes, depending on desired tone. Wipe off excess with clean, lint-free rag. 5. Ifa darker tne is desired, lt the fist coat rest or four to six hours then repeat step #4 for asecond coat. Allow sain dry for eight hours beore proceeding 6, Shake MINWAX® Wipe-On Poly container before use. Puta ‘small amount on clea, soft, lint-free cotton cloth and rub into the wood. 7. Allow finish to dry for atleast three hours (longer if conditions are hunni); when dry lightly sand again using 220-grit paper or fine steel wool and wipe clean. 8. Apply second coat and le dry 9. Allow piece to cure for atleast 24 hours 10, Position and install picture wit. VIL. Clean Up « + Ifyou have product lft over, wipe the ean rim so that product in the rim won't dry out and prevent the i from forming 2 tight sed + Clean brushes used for oil-based finishes with mineral sir VIIE. PRODUCT SAFETY DANGER! HARMEUL OR FATAL IF SWALLOWED. SKIN IRRITANT, COMBUSTIBLE. KEEP OUT OF REACH OF ‘CHILDREN. DANGER: Contains mineral pits. Harmful or fatal if swallowed. Do not take internally. Skin irritant, Avoid contact with skin and cyes, Wear rubber gloves and safety lasses when handling, Combustible. Do not use or sore near heat, sparks, lame or other source of ignition, Close container after each use. Avoid inhalation and use only with adequate ventilation, If using indoors, open all windows and doors to make sure thereis fresh air movement. If you experience lightheadedness, diziness or headaches, increase fresh air movement or leave the area. Reports have associated repeated and prolonged occupational overexposure to solvents with permanent brain and nervous system damage. Intentional misuse by deliberately concentrating and inhaling the contents may be harmful or fia FIRST AID: If swallowed: Do not induce vomiting, Call physician immediately. FOR SKIN CONTACE: Wash thoroughly with soap and water. If irvtation persists, get medical attention. FOR EYE CONTACT: IMMEDIATELY Ssh eyes thorough with ‘water, then remove any contact lenses, Continue to flush eyes with water fora leat 15 minutes. If irttation persists, get medical attention IP AFFECTED BY INHALATION: Immediately remove to fresh ai. Ifsymptoms persis, eal physician, 1X Safe Disposal of Rags & Waste Please be mindful ofthe sae way o dispose of used rags and other ‘waste, Rags, steel woo! and other waste soaked wit ll inishes ‘may spontaneously catch fre ifimproperly discarded, Place rags, steel wool and waste immediately after use in a water-filled metal container Tightly seal and then dispose of in accordance with local regulations, Be sure to keep the container out of reach of children FINISHERS TIPS + Fora clean, sharp finish, all final passes with the brash or cloth should be made in the same diredion asthe wood grain + Ifadditional surface protection is desired, apply a coat ‘of MINWAX@® Paste Finishing Wax overall exposed surfaces, Let stand for 10 minutes, then buff with a clean fiber brush (Scrub brush). Finish buffing with a clean lint-free rag, + Ifyou spot any minor imperfections in the wood (eg pinholes, surface scratches) ress the urge to use a ‘wood tlle before applying any stain. Conventional ‘wood fillers may not absorb stain in exactly the same ‘manner as adjacent wood, so the spot wil become even ‘more evident. Instead, wait unt nish has dried ‘completely and then wse MINWAK® WOOD PUTTY™or MINWAX@ WOOD FINISH™ STAIN MARKER™ for touch-ups ‘Is critial that al stains and finishes be allowed to dry thoroughly between coats. Remember, dring times :may vary due to humidity and other climatic conditions — Page 3 of 6 —"PROJECT 2 CONTINUED - WOODIWORKS: INTERMEDIATE - GHIPPENDALE MIRROR Materials Shopping Lis, nominal dimensions Cutting List, actual dimensions ae The poet ope was constructed fom bon stp pwood and soli mabogay I diferent wood are subsite, eeck or dimension lerences in siock AB vax Res" 1 pice a Uax6Urx9V4" A requied ep vax8x10" piece 5 5x9 required EF 126s piece c 2x6" 2regled ¢ From ser D A2VANGA2 2 aque uesi0x 1 (wed) E BMx1Vx BA" requ Mirror" Bx EIA x 1158 F Frame,topandbotom 34x LV8x9-54" 2 required t * Double check measurements ween ame rabbs afr pace ls asembled before cating ior oie. Miscellancons: MINWA. Professional Strength ood Glue, wide quick lease masking pe, sandpaper (100- through 20-gi, bbertands lr enough fo go avundasembled lec), ack cloth, MINWAX Be Gnishing rises, clean rags, ine sel wool, mineral prs, MIRWAX™ WOOD FINISII™ STAIN MARKERS™, wate fled met eontainer wh emer Hardware: ight o. 61/2" Daten eres, To no, 16 serene, pcre wire COMPLETED PROJECT Page 4 of 6—PROJECT 2 CONTINUED - WOODWORKS: INTERMEDIATE - CHIPPENDALE MIRROR DETAILNO. 1 MAHOGANY SPLINEG Werxaa"22" 4" (REQ) {et we Davee ae Monnse FOR MIRROR RETAINER PANEL H. ‘YB x 314° GROOVE FOR SPLINES =e 8 an FoR MiROR 1 ‘yet 36° CENTERED SNORETAINERH SURI CEN SCROLISAS B MIRROR RETAINING PANEL V — ae Sen G-—4e 5 = oma" paver. ig FoR curring ‘SPLINE GROOVES ON FACES OF MITERS. (CLAMP WORK HERE. Soeur orHen END cincutar SAW TABLE — Page 5 of 6—‘PROJECT 2 CONTINUED - WOODWORKS: INTERMEDIATE - CHIPPENDALE MIRROR , enon iis ‘ A 5 ! ‘ DETAILNO.1 aE bp : TOP # » ale SeROLLD att s ET: | sa °. ie EIN + iu Me oxi w. le A sores ie Ky Soe : | } frie i a, f : sue Des caps ] : ! grnise Fon waton : ' 4 « RETAINING PANEL DIM. } : BReTneAL FORALL T | xo FOUR CORNERS. oi = —_ 1 1/4" D. x 3/8" W. RABBET FOR MIRROR: 1] supe ro marcn nee SEATERGD OSD stor view ! “ i | spun one | /eaNeSitien ‘ 45° MITER - i bi ° e 4 203 4 5 6 = == F== FS) verano. . Pe Serou's |__| eerste ivetnareD ‘aman’ | ExGH sduane « « counts ¥, bi aA i AN nies 4 san B : KL {ileal aa —Page 6 of 6~