Mon 27 Sep, 2010
Tags: Bed, Bits, Planes, Router, Shaper, Template, Tools, Trundle, Woodworking
Picking up from where I left off in Trundle Bed Crafting – Part 1, I finished all five panels. Three panels will be framed in the headboard and two in the footboard. Just like panels in frame-and-panel construction you must add a few coats of finish to the panels before encasing them in their frame. If this step is skipped unsightly unfinished edges are visible as the panel expands/contracts through seasonal changes.
The next step in Trundle Bed Crafting is to tackle the swan necks that top the headboard. I began by printing out a full scale SketchUp drawing of one swan neck. They are mirror images of each other so all I need is one paper template. However, the swan necks are constructed with two layers glued together and the result is a 3 1/4” piece of stock. Since I need to shape four pieces, all with the same top curve, two of them share the same bottom curve, and two have a bottom curve that is 3/4” away from and smaller than the other two, I decided to make one hardwood template. Using the paper template I traced it onto 3/4” thick cherry stock being careful to arrange the grain for best strength. I rough cut the template on the band saw and completed the shaping on the edge sander.
The completed cherry template, shown left, will be used in a series of steps with template router bits. The Swan Neck presents a number of interesting challenges for the woodworker. The first one is its thickness. The Swan Neck is 3 1/4” total thickness made of a sandwich of a 2 1/4” back and 1” front. I designed it as a sandwich to make shaping easier and doable with my current collection of shaper and router bits. But even the back is wider than my longest 2” template bit.
Fortunately I have two 2” template bits; one with a bottom bearing and one with a top bearing. So I used a three step procedure to shape the Swan Neck backs. I traced the cherry template on 2 1/4” stock. I needed two of them and they need to be mirror images which was simply a matter of flipping the cherry template.
The first step in this three step procedure is to rough cut the thick Swan Neck back on the band saw. My band saw had a 1 1/4” re-saw blade mounted in it and I should have replaced it with one much narrower allowing me to follow the curves smoothly. But being lazy I simply hacked away at the stock with the re-saw blade. You can see the resulting burn marks created by a 1 1/4” blade struggling to follow comparatively sharp curves. But with no damage to the blade I was able to cut to within 1/8” of the outline making the job for the template router bit minimal. When I was done I had Side A and Side B of the Swan Neck back and the template.
The second step in this three step process it to attach the template to the appropriate side of the one of the Swan Neck backs. Appropriate side means keeping the side labels matched, for example Side A facing up on both, but with the template on the bottom. I attached the cherry template to the Swan Neck back using double sided sticky tape (carpet tape). In this step I use the bottom bearing template bit and with the template as a guide and shape all but about 3/4” of the Swan Neck as shown at right.
In the third step of this process I replace the bottom bearing template bit with a top bearing template bit, remove the cherry template, turn the Swan Neck over and use its partially shaped surface as a template. See the picture at left. I have to use this three step process on both Swan Neck backs. But I am not done; I still need to shape the Swan Neck fronts. However, they are only 1” thick and only require rough cutting and one template bit. But there are still some tricks that need to be employed to complete the Swan Necks as you will see in Trundle Bed Crafting – Part 3.