Lill's Quilt Rack: Part X, Shaping the Cross Pieces

The shaping was done! Almost.

Even after shaping the bulk of the legs with an aggressive sander, coarse, medium and fine rasps there was still much shaping to be done.

Unlike the legs, the rounding of the cross pieces began on the router.

Because the cross pieces are a consistent width (once past the flairs at the end) I was able to rough shape their curves on the router table. Then I switched to the same RAS, Shinto, Auriou, and Gramercy shaping routine.

The final bit of shaping before glue up was to the shelf. While I wanted a strong, square shelf to juxtapose against the organic curves of the legs I did east the edges with a 1/8” round over. I did this with a router and kept far away from the four locations where the legs meet the shelf since rounding them over would leave voids in the joints.

With a simple 1/8" round over the shelf was done. I wanted its square
shape to juxtapose against the curved shape of the legs.

With initial shaping done, it was time to sand. While I knew there would be much more sanding to do after glue up and final shaping, sanding the loose pieces now was relatively easy, allowing me to sand with a machine before the assembly would create spots too small to fit the sander.

I made pencil marks on the legs between each grit
and sanded until they were gone.

I sanded each leg and cross rail the same way. I would mark them with a pencil and sand the pencil marks off using my RO 90 sander with a soft platen and 80 grit paper, set to speed 1. Then I marked them with pencil again and sanded it off with the RO 90 with a soft platen, interface pad and 120 grit paper set to speed 2. I marked them with pencil a third time, this time sanding the pencil marks off with the RO 90 sander with a soft platen, interface pad and 180 grit sand paper set to speed 2. For all of this sanding, the RO 90 was set to Rotex mode. Because the rails are so narrow and don’t offer a flat surface the pressure on the sanding pad is very uneven and as a result the pad doesn’t spin properly in random orbit mode.

I also used my 6” random orbit sander to sand the shelf from 80 through 220 grit.

My what shapely legs the quilt rack has.

After this initial sanding it was finally time to begin the glue up.


In the next post, it will finally be time to assemble. For more quilt rack posts, check here.

Don't forget about the +Modern Woodworkers Association Podcast. We talk woodworking with Guests from around the world of woodworking every other week. Subscribe to the RSS feed or iTunes today.