construction of stacking unit

The above images show how i went about inserting the locating points for each join. Using the metal work lathe and a couple of cradling jigs i had constructed i was able to access the same reference points to have a consistent dowel locating system.

Once the locating points had been completed i was then able to do the glue ups for all the side members. This was made easier with the jig constructed earlier to position each side pieces at the correct shoulder height while under clamping pressure.

jig construction

As i have seperated the side components to both cut the joinery and to also provide a greater continuity to the units when stacked i required a way of locating the side elements during the gluing process as it is essential that the shoulder positions remain accurate. The jig i have created to resolve this is shown here. The crown at the bottom of the image is fixed, with the top crown adjustable to accommodate gluing up all the various heights of the sides.

The adjustable top cron shown here slides in a routered trench which keeps the crowns square relative to one another and provides enough pressure to locate the pieces accurately. During the glue up i will use clamps from either side and cauls to the top which will be more than ample to keep the whole side square and true.

Running repairs

As with the nature of timber i had alot of reverse grain sections in the American Walnut stock i had for this piece. This proved problematic as i had a limited amount of stock to work with and have been required use the majority of what i had. This meant i had areas of tear out through about eight of the elements needed for the sides of the larger bench unit. To counter this problem i created the jig shown in the image above which has a shallow curve to the top which, when used with a one to one router removes the torn grain section of the stock.

With the torn stock now removed i am left with the curve of the routing jig, i then cut and machined veneers form the limited remaining stock i had and glued this into the removed section of side pieces.

The successful result from the repair process.