Ty WOODWORKS: ADVANCED 1996-1997 CONTEMPORARY ROLLTOP DESK PROJECT Made from red oak, ths sys rlliop writing desk provide great deal of service in a small space, Based on a classic rltop desk design, the piece includes large draver as well sa pigeon hole shelf unt for added storage space. To give the piece a contemporary look, the sides are extended to serve as the legs instead of resting on traditional pedestal ‘This project will certainly challenge advanced woodworker, testing thir layout skills and ability to create and work with a router template, plough exact (mirror image) grooves as wel a curved grooves, create accurate joints with the table saw, and create a profesional-looking finish, TOOLS REQUIRED: =Peneil ~ Block plane Sanders( stationary belt, portable bel, — Ruler (rgaag or tape) ~ Assorted clamps random orbit, pad) = Square (framing, combinaton or uy) ~ Asorted wood cise Planer =4f. Tsquare, or straghteige = Saws (dove, ban, radial arm) Cordless deil-iver wit Philips deer bit Assorted les, rasps Table saw and dado head set Safety glasses Philip seremirver (medium) = Joiner — Respirator Hammer and fine nil set = Wood shaper Router (with 5/16" and 3/4” straight bis and Male (wooden or plastic) = Dril pressor portable electric dil) rounding oer bit) MATERIALS REQUIRED: See Shopping and Cutting Lists STAINING AND FINISHING PRODUCT: Finish Recommended For This Project Miscellaneous MINWAK® Pre-Stain Wood Condtoner = MINWAX fn finishing brushes = MINWAX@ WOOD FINISH™ Clean rags = MINWAK® Fast-Drying Polnurethane — Paint thinner, required = Waterfiled metal container Alternate finish choices (Choose one) vith cover = MINWAK@ PASTELS® Woed Sain —MINWAX@ POLYCRYLIC® Protective Finish = MINWAK® POLYSHADES = MINWAKB WOODSHEEN@ BEFORE YOU BEGIN and tack them to the stock using a small amoant of rubber ‘This projet requires 4/4 and 1/2” solid lumber and 1/4” cabinet sexe ie Beal pecs can at ros grade veneer plywood. Since the majority of plywood panels are Pa i sepa ovewonbohslies hen pushed coud hve 2 cece ras singe a am saw square the ‘cabinet-grade vencer on both sides. Iftwo-sided material is not ends and cut the top portion; use the bandsaw to cut the cures, 3. Rip stock to width for all rails (parts D and F) and stiles (pats B, C,E) forthe sides and back; cut pieces to length available, you can affix exile veneer to the appropriate surfaces. ‘Hlexible veneer is widely available, comes in wide rolls and is easy ea (see ctng list for exact measurements). 4. Mark each pec forthe entered prove and tenon cuts PROCEDURE: Note: All tenons and grooves are 1/4” wide x 3/8” deep unless othervise indicated. Refer to diagrams for groove 1. Carcase — Layout and Cutting length information, 1. Start by laying out the two curved rails (part A). For 5. Set up dado cutter on the table saw to cut the centered accaracy, make ull sie paper pattern foreach of the 0 ‘grooves. Noe: The grooves in he side sie (part) stop 7” pieces (see diagrams for dimensions); carey cut them out fea oie = Page 1 of 7 —‘PROJECT 3 CONTINUED - WOODWORK: ADVANCED - CONTEMPORARY ROLLTOP DESK BUILDER'S TIP: Pus two tape markers onthe save table opposite the lead and tal points. The two markers will guide ‘you when making the parial groove cuts atthe start or end of ‘arun. This procedure also enables you to face the same side of each piece against the rip fence, which wil belp you avoid ‘any problems due to inconsistencies instock thickness (a ‘common occurrence in hardwoods) 6, Using 1/4” chisel, square the ends of the stopped grooves (parts BCE) 7. Setup atenoning jg for the grooves onthe top ends of the fron stile (part C). Cut grooves. ‘8. Next, ut the tenons on the rails (parts A, D, ). Start by ‘making the shoulder cuts (width eut)on both sides of exch end. Note that twill benecessary to shift the guide board to the other side of the lade for half ofthe cus. ‘BUILDER'S TIP- The shoulder cuts on the curved rails (part A) are best done on a radial arm sae. Clamp a square board in place against the fenceto serve asa stop to gauge the depth ofthe cus and to align the curves. Abu the end ofthe rail ‘against the stop, then make the cuts Then, use the table saw to make the cheek cuts (length cut), Note: Ifyou bave a muli-bade dado set you can make both cheek cuts in one pass by using only th to outside Blades ‘and a 1/4" spacer. Otberwise, make two passes wilh a conventional blade 9. Next, cut the grooves inthe edges ofthe curved rails on a shaper with a 1/4"-wide etter. Ifyou don't have access to a shaper, you can cut the grooves by making several passes with ‘router fitted with ast cuter. The slot cutter will cut U2" deep although only 2 38" deep groove is required. Thisis of ‘no consequence; you need only adjust the dimensions of the plywood panel inset. BUILDER'S TIP: Ifyou must use the router to create the ‘grooves on the curved ras, for best results make each groove ‘in several slow passes, wtth each succeeding cut slightly deeper than the previous one 10, When the ongues and grooves have been completed, setup the dado head to cut the two stopped wide rabbes onthe two back stiles (part B), The rabbet should be 5/16” deep x 13/16" wide, coming to slightly rounded stop 7” fom the bottom, 11, Nex, sand al the inside edges ofthe stiles and rails. Dry assemble the pieces and measure the grooved openings for te plywood inserts (pats 6,141). Sand the sharp corners of ‘the frame at this time; wipe clean, 12. Cat the plywood panelsto size. Ifyou need to apply the Flexible veneer, do so now. Cut the veneer slighty oversize ‘and attach with appropriate amounts of eneer glue or contact cement, Trim of overhang, Allow lue to set 13. Lay out and cut desktop slab (part L2). To star, rough cut a pair of boards to be edge-lued. Align the boards so they present the most pleasing visual grain; mark the mating pieces forthe biscuit locations. Cut biscuit grooves with plate joiner. Apply carpenter’ glue to board edges and biscuits; join boards, making sure ends are aligned, and clamp together using bar clamps, Set aside for at least four hours ‘When glue is completely dry, remove clamps and cutto size. 14 Lay out and cut the desk top (part L1) to size. Cut the tambour stop (part K2) to length, sand smooth and fix to underside of desktop, 1/2" back from front edge. Set assembly aside. IL. Assembly ~ Back and Side Frames 1. Assemble back frame. Apply lue to tenons on bottom rail (par F) and inset into the back stiles (part. Slide in bottom plywood pane! (part G) followed by the middle rail (part F). Then, slide in the top plywood pane (part H) followed by the third and final ral (part F), which should have glue on the tenons. Clamp pieces in place and set aside to dry. When dry slightly round the botiom auside edge of the ses (part B) to mate withthe rounded rabbes inthe side sles (part B). 2, Assemble side frames. For each, start by applying glue to tenons on the bottom rail (part D) and insert into the side stiles (parts C and B). Slide in bottom plywood panel (part), followed by the middle rail (part D), Finally add the upper plywood panel (part) and the curved ral (art A). Set assemblies aside overnight, 3. When the glue has dried, sand the faces of the frames, ‘Then, use the router with a straight cutter to make the dadoes (1/8" x 13/16") in the sides and back forthe deskiop slab (part 2) 4, Create a plywood template (see diagram) to ut the grooves, inthe sides that will receive the sliding tambour door. Cut ‘out the template witha band or jg saw and carefully sand away any blade marks, 5, lay out the template on the fis side frame, setting it back 15/16". Tack template in place 30 its curved edge is parallel to the curved edge ofthe curved ral, Then, use 25/16" siameter straight cuter with a routeremplate bushing guide to cut the grooves. Repeat for second side. Note: Take extra ‘care when positioning the template on the second side, a the ‘tambour door grooves need to be exact mirror images. ML, Tambour Door 1. The 25 tambour slats (partN) are ripped from 1/2” stock on the table saw with the blade tted at a 10 degree angle. A molding head cuter with a small radius cure is used to round the slat comers, Note: Use a feather board to keep the pieces snug against the rip fence. 2 Cut sats to length (see plans for dimensions). To cut the end rabbets onthe underside of each slat, start by aligning the ‘ends and taping them together. Then, clamp on a guide stick ‘and make a pass withthe dado head on the radial-arm sav. Using 2 guide stick helps you cut ll the rabbets atthe same time and guarantees that they will ll have the same dimensions, Sand surfaces smooth and wipe clean 3. Apiece of 10 oz, canvas (part P) is used to jon the slats. TO assemble, start by taping the square yar of eanvas tothe workbench. Then, carefully lay out and tack down two guide strips — one along the back, the other along side — ‘making sure the strips meet ata right angle. Note: The side — Page 2 of 7 =PROJECT 3 CONTINUED - WOODWORKS: ADVANCED - CONTEMPORARY ROLLTOP DESK guide shouldbe less than 1/4 thick to permit the rabbet shoulders to abut accurately. 4, Starting from the back edge and working forward, position and join the 25 sas tothe canvas using contact cement. Note: Itis imperative that you read and understand all contact cement applicaion and safety instructions before proceeding with this step. After the 25 slats are in place, ‘complete the door by afixing the tambour’s bottom rail (part ‘M-- see diagram for dimensions) tothe front and retaining strip (part 0) on the backside ofthe canvas aligned behind the bottom rail. The knobs wil be attached to the bot rail ‘and secured with screvs drilled through the retain strip 5. Set tambour door assembly aside overnight. After cement has set, postion door knobs on tambour's boom rail 4" in from each end, Mark the knob location; dril holes for screws, Insert screws irom back side trough retaining strip; serew Kanobs into place IV, Assembly 1. Bore plot holes forthe screws in the tp (part Lt), back. frame and side frames, using a 1/16" drill bit (see diagram for hole placement). Then, dry assemble the desk with desktop slab inserted snd hold pieces in place with bar clamps. Now, continue drilling the pilot holes into the desktop slab and into tre top edges ofthe vertical members. 2. Disassemble the piece and finish driling to counterbore and enlarge serew holes inthe outer members 3, For the sake of convenience, its wise to sand, stain and fish the inside surfaces ofthe desk at this stage, while the piece is clsassembled (See Seaion VD. 4, When the finish i dry, assemble the desk. After applying glue to the mating surfaces, attach the first side frame and the desktop slab to the back. Screw the pieces into place and wipe away any excess gue. Insert the tambour unitinto the frst side; attached the second sie and finaly the top. Serew the pieces int place. 5. As the final ste, cut the required number of wood plugs ‘Squirt lue into etch serew hole and press plugs into place to conceal screwheads. possible, allow plugs to rest over night before sanding, Projecting plugs shouldbe sanded flush with cabinet surface using 120-grit paper inthe random ‘orbit sander. Fnish all carcase sanding using 150-grit paper in the pad sander always working withthe grain, , Pigeon Hole Shelf Unit (PHSU) and Large Drawer 1, With the desk assembled, the PHSU and large drawer now can be constructed. To stat, remeasure the desk to determine accurate dimensions for the two pieces. Ifnecessary, alter the dimensions in the plans to suit. 2 Lay out and cut the recuied members (pats Q through DD) to size. Plough the necessary rabbets (See diagram for dimensions) in the PHSU top (part), PHSU drawer fronts (part AA) and larger drawer members (parts Q and R), 3. Dry assemble the PHSU and large drawer to check for fit and site, Make any necessary adjustments. 4, Agua, forthe sake of convenience is wise to sand, stain and ‘ish the PHSU and drawer while the pieces are disassembled (See Section VD. 5. When the finish is dry, assemble PHSU and drawer using straightforward construction techniques. ‘BUILDER'S TIP: Since the sides, back and bettom of the two ‘small drawers in the PHSU are made of 1/4" plywood stock, cand will carry litle weight, they can be assembled using ‘Simple butt joints and brads, However, the front pieces (part ‘AA) are made of oak and wil require rabbets for assembly as indicaled previously. 6. Locate and bore holes for the large and small drawer knobs, Attach knobs. 7. Finally, ay out and cut the rails (part Kt) forthe large drawer (see plans for dimensions). Position rails on inside ofeach side frame and mail into place. ‘8 Install PHSU and drawer into desk assembly Vi. Sanding, Staining, Finishing 1. Read and follow abel instructions forall produc 2. Sand surfaces smooth, then wipe with atack cloth to remove all traces of dust 3. If working witha soft wood, such as pine, apply MINWAX@ Pre-Sain Wood Conditioner according to label instructions. Wait 15 minutes, and wipe awey excess using a clean rag 4, Within two hours, apply the MINWAK® WOOD FINISH™ of your choice to all surfaces sing a clean brush and with-the- grain strokes. Remember to stir the stan well - do not shake, low stain to penetrate for 5-15 minutes. Wipe off excess vith clean in-free rag, Additional coats may be applied for deeper color. Allow to dry at least 4-6 hours between coats. BUILDER'S TIP: To achieve a subtle “pickled” appearance, use MINWAX® PASTELS® Summer Straw. 5. Slir MINWAK® Fast-Dryng Polyurethane before and during use, Do not shake, Using a natural bristle brush, apply thin coat to all stained surfaces per label instructions. 6. Allow finish to dry for at least three hours (longer if conditions are humid); when dr ight sand again wsing, 220-grit paper and wipe dean. 7. Apply second coat and let dry. When dry, install the drawers knobs. 8, Allow finish to cue for approximately to weeks. Optional Stain/Finish: For stain and polyuretbane protection in one easy step, 1s ‘any MINWAX® POLYSHADES® or MINWAK® WOODSHEEN® color according to label instructions. VII. Glean Up ‘Ifyou have product left over, wipe the can rim so that product in the rim won't dry out and prevent the lid from forming a tight seal ‘+ Clean brushes used for oil-based finishes with mineral spirits; soap and water are all that is needed for brushes used for water clean- up products such as MINWAX® POLYCRYLICO Protective Finish. Page 3 of 7 =PROJECT 3 CONTINUED - WOODWORKS: ADVANCED - CONTEMPORARY ROLLTOP DESK VIII. PRODUCT SAFETY DANGER! HARMFUL OR FATAL IF SWALLOWED. SKIN IRRITANT. COMBUSTIBLE. KEEP OUT OF REACH OF CHILDREN. DANGER: Contains mineral spirits. Harmfl or fatal i swallowed. Do not take internally. Skin irritant, Avoid contact with skin and ‘yes. Wear rubber plves an safety glasses when handling Combustible. Do not use or tore near heat, sparks, lame or other source of ignition, Close container afer each use. Avoid inhalation and use only with adequate ventilation. Musing indoors, open al windows and doors to make sure there is fresh air movement, If you experience lightheadedness, dizziness or headaches, increase fresh air movement or leave he area. Reports have associated repeated and prolonged occepational overexposure to solvents with permanent brain and nervous system damage. Intentional misuse by deliberately concentrating and inhaling the contents may be harmful or fatal FIRST AID: If swallowed: Do not induce vomiting, Call physician immediately. FOR SKIN CONTACT: Wash thoroughly wih soap and water. If irritation persist, get medical attention. FOR EYE CONTACT: IMMEDIATELY flush eyes thoroughty with ‘wate, then remove any contat lenses. Continue tous eyes with ‘water for a least 15 minutes. If inritation persists, get medical attention. IF AFFECTED BY INHALATION: Immediately remove to fresh ait. symptoms persist, call physica 1X. Safe Disposal of Rags & Waste Please be mindful ofthe safe way o dispose of used rags and other waste, Rags steel wool and other waste soaked with ol nshes ‘may spontaneously catch fireif improperly discarded. Place rags, steel wool and waste immeditely afer use in a water-filled metal container Tightly seal and then dispose of in accordance with Local regulations. Be sure to keep te container out of reach of children. COMPLETED PROJECT FINISHER’S TIPS + Most woodworkers agree that raw wood should be sanded to atleast the 150 grit stage, before applying, any finishing materials. Sandings benweer coals should e done with 180 to 220 grit abrasives. ‘+ Ifyou're working with a waterbased finish, suchas, MINWAX® POLYCRYLIC® Protective Finish, don't use the standard tipping-off procedure, Instead: (1) Transfer ful brush-load to the surface and quickly spread using with-the-grain strokes. (2) Immediately use eros-rain strokes o eliminate any ‘chance of holidays (mised spots). (3) Complete ‘sing with-the-grain strokes across the ul length of the surface, being careful not to leave anyheavy spots. ‘+ When additional surface protection is dese, apply ‘wo or three coats of MINWAX® Paste Finishing Wax ‘overall exposed surfaces. Let stand for 10 minutes, then buff with clean fiber serub brush, Finish buffing with a clean, lint-free cloth, + is critical that all stains and finishes be allowed to dry thoroughly between coats. Remember, drying times can vary due to humidity and other climatic conditions. — Page 4 of 7—‘PROJECT 3 CONTINUED - VOODWORKS: ADVANCED - CONTEMPORARY ROLLTOP DESK Materials Shopping List, nominal dimensions ‘Wile sk was used in the proton, mahogany, cher), wou and een pine are egal sable woos fortis projec. Ia diferent wood i substued, make cera to check or dimensional diferezes instock. ‘Quantity Nominal Dimensions Material pe var xe xT? Red oak pe V2 x8°x96 Red ook pe vr xe xe ed oak pe 18°96 Red ook ape x12"x96 ed oak pe 48x" Red oak double sided veneer rade pweod elope) 18396" ted ak ele vener (noe: Tse minum sir avaale, act ste needed, Aoecessay, i 162607) 1 sq yard Cass 3 model no. BP.724-50, Amerock lacs (or equaen) 2 model no. BP-725-30, ‘Amerock les (requalem) 16 mw ‘Wood pls (at fom red oak) 8 Batar rood dowels Cutting List, actual dimensions Belote ung pieces sie, dble-chec all measurement. This ay, ee any deviation fom the dimensions shown in he ravings, you can change dem o sai the pec ou are ulin, Be tet mark ay dimension changes in coor on the rg daigs. Key Part ‘cual Dimensions Pes. Required ‘ (ured rls ‘ot bot om one Board 2 (6 x10-12"x30") B Stl (sides) 6 3°42 2 c Sie (des) 1yig e322" 2 D al (es) 1ylGex 3x 16g 4 E Sle (back) 1ylorx 3038 2 F al back) yes" x23. 3 s Back pal (ep) Ua" ICUs aI 1 (vod) 4 ‘Back pnd (bxlom) Ue x1La sas 1 (yweed) 1 ‘Sie panel (boom) Wa 1434's EL 2 ¢phwood) i Side panel (op) Us 14s 46 2 (plywod) x Driver ral 1316" 78 ITE a a “ambour sop 1/16" x 30x28" 1 u ‘Top 16" x81" 30" 2 Desktop M16" x 19.38" 2858 ™ Tambodrbotwn ral x 1385 28-78" N Tamboor sas Vax 328-708" 0 Retning 9 Mex 22778 P amas Tq.yand Q raver (romand back) 116" x 24/8" 28.08" R Drawer (ses). Ya x2 x1 s Drawer (bot) sex 18.2758" r PSU top abot Vax SU" 288 v PSI sides. WarxSuex v PSU are ders yanssaesi w PSU small ders Massie 8 x PSU hehe xSili'x 8 y HSU fascia foeard z HSU back exis sie" M HSU sm.drave ot) V2 x76" 2738 a HSU sm, dave Chach) var x2 76" 27.38 oe ist sm, dave (side) 276035) pp PSU sm. dave (in) Wars hyE x78" Hardware 192-V2" no, 12 Dathead wond sre; to 1-1/4" no, 12 Dated wed sre; 61" no, 12 Mathead wod screws Miscellancous: [MIWA Professional Strength Wood Ge, MINWAX in nihing brushes, tack lo, clean rags, watered meal cotanr with i, MINWAN® Sanding Block (100- ‘hrough 220 ge), MINWAX® WOOD FINISH™ STAIN MARKERS" mineal sis, contac cemen. * amverock reseed tadenak of Newell Operating Company. = Page 5 of 7-‘PROJECT 3 GONTINUED - VOODWORKS: ADVANGED - CONTEMPORARY ROLITOP DESK x Leese lear (eos) we pee foe . eo ee 5 7 w wit ote 8 Er 6 id RABoET DETAILFACIAY (ack) se pst yb set S Nore: eee ‘ToNGues ano crooves RABBET ‘We WDE 3 a" DEEP ‘ausoun aroove An, FOUTeR SISTED an, Deal 2 Tham | ci ze, RABBET 1 xsi16" : ‘Groove FoR +— 14-94} ‘TAMBOUR MoRTise AND ar ‘TENON DETAIL |~ SMALLER For ROUTER BUSHING CLEARANCE Ye pLywoon ‘TEMPLATE. Page 6 of 7—‘PROJECT 3 CONTINUED - WOODWORKS: ADVANCED - CONTEMPORARY ROLLTOP DESK ese rust nowt view ue errgoewew "4 te nina coe i —T — * w. 5 iM v Eu x v4 ¥ 2 x oO x fe] ~ aa ‘TAMBOUR, SECURED TO. Ganvas Witt Sonract ‘TAMBOUR ASSEMBLY ‘ue* RADIUS’ Page 7 of 7—