Assembling The End Units

2 Cutting the half-lap joints

All of the dadoes and rabbets for the half-laps used to assemble the end units can be cut on the table saw (photo, above)—except for those on the back edges of the rear legs for the back seat rail. These are cut on a band saw because the cuts are located on the inside of the leg curves, and the stock cannot rest flat on a table saw table at these points. Start by making all the table saw cuts, then outline the remaining dado on each rear leg. Feeding the stock into the blade with both hands, cut the sides of the dado with two cross-grain cuts, then make a series of curved (above) and straight cuts to remove the remaining waste.

1 Making the rear legs

Referring to the anatomy illustration and cutting list on the preceding pages, cut the arms, arm support slats, and the end and stretcher rails. To outline the curved rear legs on the stock, start by making a plywood or hardboard template; the legs are vertical from their bottom ends to the seat and then curve backward at about 10°, an angle that most users will find comfortable. Once the template is ready, trace its outline on the leg stock with a pencil. Using a 2-by-6 will enable you to use the same blank for both legs (above). Cut the legs on your band saw.


Rear-leg outline

Rear-leg etock

Front leg

Kear leg

3 Attaching the end and stretcher rails to the legs

Set front and rear legs from the same side of the bench outside face up on a work surface and apply waterproof glue in the dadoes. Tap the end and stretcher rails in position, check the unit for square and drill pilot holes in the rails, two at each end of the end rail and one into the stretcher rail. Screw the pieces together (right).

Front leg

4 Installing the arms

Screw the arm support slats to the end rails, making certain that the supports' bottom ends are flush with the bottom edges of the rails. Then, holding one leg assembly upright, set the arm in position, centering it on the supports and butting the back end against the rear leg. Outline the supports on the underside of the arm and cut a '/^-inch-deep mortise into the arm within each outline. Also bore two clearance holes through the arm in line with the front leg and through the rear leg into the end of the arm. Next, spread some glue in the arm mortises and at the points where the arm contacts the legs, fit the arm in position again (left), and screw it to the legs.

Kear leg

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Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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