Cutting Diagram

All of these molding cuts are made using six bits; Vz" cove, roman ogee, Vz core box, a rabbet bit (any size), and both a W and W' quarter round.

the crown. The crown consists of three pieces, all with different molded edges, see Fig. 12. The first piece (H) is cut to size and routed with a roman ogee bit. After this piece is routed, there should be a Vs" lip hanging over all four edges of the top of the case, see Fig. 14.

Note: This piece is the same size as the base (K), so 1 cut them at the same time.

The next piece (I) is cut 1" smaller (in both dimensions) and routed in two passes with two different bits: a Vz" cove bit and then a straight bit.

The third piece for the crown (J), is cut to size 1 Vz smaller than the second piece (I), and routed with two bits: a Vz quarter-round bit and a Vz" core box bit.

the base. The base piece (K) is identical to the bottom crown piece (H). The feet are cut to size from '//-thick stock (see Fig. 13), and routed with a Vz" quarter-round bit on the three outside edge and a Vz" cove bit on the inside edge, see Detail A, Fig. 13.

assembly. When gluing these pieces together to form the crown and the base, they have a tendency to slip around before the glue sets. To prevent this, I clamped them together and drilled holes for alignment dowels to hold the pieces steady as they're glued together.

the handle. Before mounting the crown to the case, drill Va holes through all three pieces of the crown, counterbor-ing the bottom piece, see Fig. 14. Also counterbore the top (E) of the case so the screws (and handle) can be removed when the finish is applied. Finally, both the crown and the base can be attached to the case using #8x1 Va" woodscrews.

final assembly. Now the door can be mounted by cutting mortises for the door hinges. Then I installed the plywood back with turn buttons mounted on the back edge of the case sides. And finally, I mounted the clock works, following the instructions that come with them.

finishing. To finish the clock case, I applied four coats of Tung Oil high-luster finish. (Available from Garrett Wade, 161 Ave. of the Americas, NY, NY 10013).

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Wood Working for Amateur Craftsman

Wood Working for Amateur Craftsman

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