Construction began by mocking up the frame with some peg board scraps I had. Once I was satisfied with the dimensions, I milled the walnut. Luckily, I had success with a new jointing technique and didn’t turn any of my walnut into wedges while I was milling the the frame.
After quickly cutting the four, rectangular frame pieces to size, I used my new Woodpecker spacer blocks to relatively dimension the table saw fence and blade location. I then quickly cut the rabbets in the rails using two passes on a standard table saw combination blade. For the stopped rabbets on the stiles, I first marked the rail locations so that I would know where to stop. I then milled the stile rabbets using a router and a bearing guided rabbeting bit.
|A holy version of my frame.|
Once the rabbets were completed, I broke out the trusted Domino and milled my joinery. I again used my Woodpecker spacer blocks and referenced all the Dominos using the integral alignment pins and relative dimensioning.
|I made the rabbets in the stiles a little extra long. By going long, I didn't have to square them off.|
Once dominoed, it was time to mill the cloud lift in the upper rail. To do this I made a very simple jig that held the workpiece and Marc’s templete and allowed me to bring the piece to a bearing guided flush trim bit in the router table. I didn’t initally clamp the templete tight enough and it drifted, but I was able to simple enlarge the cloud lift sightly, re-clamp and carry on. It was only a slight enlargement and no one but you (dear reader) is the wiser.
|Everything is made better with relative dimensioning.|
With the rails and stiles now completely cut and shaped, I broke out my new DeWalt DWP611PK and put an ⅛” roundover on all the exposed frame edges.
|My quickie cloud lift fabrication setup.|
When the shaping was finally over, I sanded the parts. This was a simple matter of hitting their faces with 80, 150 & 180 grit paper on a random orbit sander and using corresponding grit sanding sponges on the edges and round overs.
Next up, plugging the frame.