Académique Documents
Professionnel Documents
Culture Documents
PROJECT
FRETWORK
PICTURE
FRAME
With a scroll saw and
a few extra hours, you
can turn a plain frame
into this elegant one.
NOTE: Frames
sized to hold
3 x 5 photo
I realized that 3x5 photos arent exactly 3" by 5". So if you have a particular picture you want to put in this
frame, cut the panels to match your
photo. (My panels were 31/2" x 43/4".)
Once the panels are cut to size, it's
time to cut the fretwork pattern in
one of the panels. So set the other
a.
4!/4"
FIRST:
Cut frame
blanks
to size
!/2"
4!/4"
Rip
fence
!/2"
#/4" x !!/16"
brass hinge
b.
5!/2"
Router
fence
SECOND:
Round over
edges of
each blank
5!/2"
!/8" round-over bit
c.
PANELS
(!/8" x 3!/2" - 4#/4")
!/8"
Deep
groove
FRAME PIECES
(!/2" x !/2")
24
#4 X !/2" Fh
woodscrew
Woodsmith
Center !/8"
groove
on blank
No. 103
Photo
Acetate
a.
#4 x !/2" Fh
woodscrew
#2 x #/8"
Brass
screw
!/2"
Full-size Patterns
No. 103
Woodsmith
25
Night Light
Light up the night with four interchangeable patterns featuring enchanting scenes that are sure to
please your child. All it takes to build it is a scroll saw, a small light bulb, and a weekend in the shop.
78
SCROLL SAWN
be easy to come up with hundreds of different ideas for your own panels. Ive
included four examples for the panels in
my Night Light. Each has a magical
quality that will look nice in a childs bedroom or sitting on a hallway table or
stand. (You can find the patterns in the
Designers Notebook on page 82.)
WOOD. I used cherry for all the parts
of the Night Light. The color and warmth
of cherry enhance the glow cast by the
light. And because cherr y is closegrained, it cuts well on a scroll saw.
SUPPLIES. The light fixture is a
Christmas-tree-size (4-watt) bulb that
clips tightly into the base of the box. This
EXPLODED VIEW
OVERALL DIMENSIONS:
6W x 51/4D x 9H
C
LID
BACK
PANEL
A
D
LID BLOCK
DIVIDER
PANEL
A
INTERCHANGEABLE
PANEL
A
SIDE
B
B
SIDE
LIGHT BOARD
E
LIGHT FIXTURE
BASE
C
MATERIALS LIST
WOOD
A Panels (6)
B Sides (2)
C Base/Lid (2)
D Lid Block (1)
E Light Board (1)
1/
4
3/
4
1/
2
1/
2
1/
8
CUTTING DIAGRAM
#/4 x 5!/2 - 36 (Two Boards @ 1.2 Bd. Ft. Each)
D
x 43/4 - 8
x 43/4 - 8
x 51/4 - 6
x2-4
x2-4
HARDWARE SUPPLIES
(4) No. 6 x 1" Fh woodscrews
(1) Felt cloth (6" x 6")
(1) Night light socket switch w/ cord
(1) 4-watt frosted bulb
NIGHT LIGHT 79
RESAWN PANELS
SIDES
After resawing and cutting the six panels
to size, the next step is to make the
grooved sides of the box.
SIDE BLANK. The two sides (B) start
out as one blank of 3/4"-thick stock. Cut
the blank to finished width (43/4") and
rough length (161/2") (Fig. 3).
PANEL GROOVES. Next, cut three 1/4"wide grooves for the panels to slide into.
SECOND:
POSITION FENCE
SLIGHTLY MORE THAN
!/4" FROM BLADE
PANEL BLANK
(#/4"-THICK STOCK 4#/4" x 26")
MAKE TWO
PASSES,
FLIPPING
WORKPIECE
END FOR END
BETWEEN
PASSES
8
4#/4
FIRST:
SET RIP BLADE
TO CUT 2!/2"
HIGH
SLIDE SIDE
PIECE AGAINST
FENCE TO
TRIM EDGES
B
SIDE
BACK
EDGE
B
SIDE
NOTE:
USE TEST PIECE
TO CHECK CUTS
#/4
8
ALL GROOVES
ARE #/8" DEEP
4#/4
!/4
!/4
!/4
2
RIP
FENCE
!/2
TRIM FRONT
AND BACK EDGES
OF SIDE PIECES
TO !/2" THICK
SET BLADE
#/8" HIGH
!/2
ROUTER TABLE
FENCE
ROUND OVER
OUTSIDE EDGE
1
B
SCROLL SAWN
SIDE
B
SECOND: CUT
DIVIDER GROOVE
80
A
PANEL
(CUT SIX PIECES
!/4" THICK)
#/8"
ROUNDOVER
BIT
!/4
7
ROUND OVER
INSIDE EDGE
B
!/2
8
5!/4
NOTE:
11
B
SIDE
!/2
C
BASE
BOTTOM SIDE
OF BASE
!/2
C
LID
BASE
C
BASE
!/2
FINGER
HOLE
a.
10
C
(BASE ONLY)
ROUTER TABLE
FENCE
WASTE
NOTE:
ROUT ACROSS
END GRAIN FIRST
1#/4
BORE
TWO
1"-DIA.
END HOLES
FOR FINGER SLOT
12
!/4
#/8" ROUNDOVER
BIT
13
CHAMFER
EDGES
SIDE
STORAGE
CHAMBER
&/8
C
LID
&/8
!/2
LIGHT
CHAMBER
D
LID
BLOCK
(!/2" THICK)
NOTE:
!/4" INSET
ON ALL SIDES
#6 x 1" Fh
WOODSCREW
a.
a.
BACK
FRONT
!/4
PILOT
HOLES
&/8
BASE
NOTE: PAINT
LIGHT CHAMBER
WHITE FOR
BRIGHTER GLOW
a.
CL 1"-DIA. THROUGH
HOLE
!/4" INSET
COUNTERSUNK
SHANK HOLE
C
LID
CHAMFER
EDGES
E
LIGHT BOARD
(!/8"-THICK STOCK)
LID
BLOCK D
E
LIGHT
BOARD
CL
#/4
&/8
CUT
TO FIT
CUT
TO FIT
NIGHT LIGHT 81
Perfect for a childs bedroom, these Night Light patterns provide a soothing glow when its needed
most. A hidden compartment inside the light holds the three extra panels when theyre not being used.
PATTERNS
The magic of the Night Light is in
82
SCROLL SAWN
FALLING STARS
JACK OLANTERN
ENLARGE 200%
ENLARGE 200%
CAT FISHIN
SNOWY PINE
ENLARGE 200%
ENLARGE 200%
SCROLL SAW
PROJECT
SCROLL-SAWN BOOKENDS
The scroll-sawn panels and brass plates make
these bookends both attractive and functional.
BASE
As I mentioned earlier, each bookend
is really just a picture frame that sits
on top of a base, see Base Exploded
View. I started with the base, which
is two pieces of solid wood, plus a
rounded brass plate.
MOLDING. The first piece to work on
is the base molding (A), see Base
Exploded View. Its only 1/4" thick so
youll have to plane down some stock
first. (If you dont have a thickness
planer, you can resaw what you need
on the table saw, see page 15.)
With 1/4"-thick stock in hand, you
can cut the molding to rough size. I
cut mine to finished length (6") but left
it extra wide at this point (31/2"). This
not only made the piece safer to work
with, it also allowed me to cut two
molding pieces from each blank.
(Though theres only one of each
bookend shown in the photos at left,
I actually made them in pairs.)
Next, I rounded over the edges of
the oversized blank with a 1/8" roundover bit, see Fig. 1. Since two pieces
are being cut from this blank, all four
MATERIALS
(For one bookend)
A
B
C
D
E
F
20
Woodsmith
!/4 x 1!/4 - 6
#/4 x 1&/8 - 7!/4
#/4 x 1 - 5!/2
#/4 x 1 - 7!/4
!/4 x 4!/2 - 6!/4
!/4 x !/4 - 28 ln. in.
a.
b.
a.
a.
a.
b.
Woodsmith
21
Bookend Frame
{ The frame
and scrollsawn panel
are glued to
the top of
the base.
a.
22
a.
a.
a.
Woodsmith
No. 126
a.
mitered
to fit in the frame, see Panel
Exploded View. Then the pieces can
be glued into the frame behind the
scroll saw panel.
BRASS OPTION. Or for a different look,
you can place a piece of 30-gauge
a.
a.
a.
Pineapple
No. 126
Stag
Woodsmith
(Enlarge 200%)
Classic scroll
23
Weekend Project
34
4 x 1 - 183 4
3
4 x 78 - 612
1
4 x 14 -1712
1
4 x 14 - 6
1
2 x 512 - 20
3
4 x 3 4 - 17
1
4 x 418 - 4
G Small Fretwork Panel (8)
1
H Large Fretwork Panel (2)
4 x 418 - 8
3
3
(1) 6 8" x 17 8" Beveled Mirror
(2) Keyhole Hangers
(4) #8 x 112" Fh Woodscrews
(20) 18-ga. x 3 4" Brads
Woodsmith
building the
17!/2
FRAME RAIL
1
18#/4
FRAME
SIDE
MIRROR
STOP
6!/2
Beveled Mirror
6#/8
BOTTOM
MIRROR
STOP
NOTE:
Frame rails and
stiles are #/4" thick.
Mirror stops are !/4" thick
17#/8
B
#/4
a.
FRAME
STILE
!/4
b.
!/8
!/4
SIDE
SECTION
VIEW
!/4
!/8
!/4
18-ga. x #/4"
brad
Mirror
&/8
NOTE: Cut tongues
on sides of frame
after assembly
!/2
!/4
!/4
a.
END VIEW
!/4
Dado
blade
Aux.
fence
a.
Dado
blade
www.Woodsmith.com
a.
Aux.
fence
Dado
blade
!/4
Mirror
frame
!/4
!/2
END
VIEW
Aux.
fence
Aux.
fence
Aux.
fence
Aux.
fence
Cut tongue on
mirror frame stile
edges only
END
VIEW
!/8
Frame
!/4
4!/8
SMALL
FRETWORK G
PANELS
18-ga. x #/4"
brads
4!/8
a.
Shelf corner is
4 notched to fit
around upright
Keyhole hanger
with screws
5!/2
E
4!/4
SHELF
20
4!/8
Mirror frame
tongue fits into
groove in upright
#8 x 1!/2"
Fh
woodscrew
LARGE
FRETWORK 8
PANEL
b.
17
H
F
UPRIGHT
SHELF
4!/4
c.
adding the
SHELVES & FRETWORK
With the frame complete, you
can focus on adding the uprights,
shelves, and the fretwork.
THE UPRIGHTS. Each upright has
a pair of grooves in the front
and inside edges, as you can
see in detail a above. The mirrored frame will fit in the inside
grooves, while the fretwork will
fill in the rest of the grooves.
a.
E
String
5!/2
Workpiece
Clamp
END VIEW
Aux.
fence
#/4
Aux.
fence
String holds
hardboard
to desired
arc
#/4
E E
SHELF
a.
Dado
blade
Pre-drill pilot
hole for brads.
See pg. 33
for more
information
How-To:
Cut Fretwork
The fretwork adds the perfect touch
to this wall shelf. But before you sit
down at your scroll saw, theres a
little preparation to be done.
PREPARING THE WORKPIECES. The rst
step is to size the workpieces.
Instead of planing thick stock
down to 14", I decided to resaw
the stock to the proper thickness.
After planing the resawn stock
smooth, I cut the pieces to finished
size and mounted copies of the
patterns you see on the far right to
the blanks with spray adhesive.
PREPARING THE SCROLL SAW. Now that
the workpieces are ready, make
sure your scroll saw is too. First,
its important to have the right
blade. For fretwork, I generally
use a No. 5 reverse tooth blade
and tension it so it will only ex
1 " under nger pressure. Then
8
square the table to the blade.
Now youre ready to cut the
fretwork. But the place to start is
actually at the drill press.
STARTER HOLES. Because the fretwork involves mostly inside cuts,
drilling starter holes will allow
you to feed the blade through the
workpiece to make those cuts.
With fretwork, what takes getting used to is rotating the panel
as you work. To make this easier, I
drill holes near sharp turns (Fig. 1).
Its easier to rotate the workpiece
inside a hole than in a kerf.
MAKING THE CUTS. After the holes
are drilled, you can begin cutting.
Theres no set sequence, but I like
to make the smaller cuts rst. Cutting out the large areas rst can
weaken the workpiece and may
cause it to break when cutting the
smaller areas.
REMOVING WASTE. Its easier to
remove the waste in small pieces,
rather than all at once. For example, Ill cut sharp corners in two
or three steps (Fig. 3). For other
corners, the trick when rotating
the panel is to push the workpiece
against the sides and back of the
blade (the edges that dont cut.)
www.Woodsmith.com
!/8"-dia.
twist bit
1
Drill !/8" starter
holes at outside
corner locations
of fretwork pattern
Waste
NOTE: Attach
pattern to blank
with spray adhesive
SECOND: Reposition
workpiece to relocate
blade at starter hole
and start cut in
other direction
Connect the Holes. By drilling holes at turning points, its easier to rotate the workpiece
and stay close to the layout lines.
3
SECOND: Back
out of cut and
loop around from
the other side
THIRD: Spin
THIRD:workpiece
Reverse
direction
toto
around
continue
continue
cutting
removing
out
from the
waste
corner
6
Removing Waste. With intricate designs,
its much simpler to cut away the waste
in small pieces, rather than one large cut.
Woodsmith
Making several cuts from different directions in the pattern will leave sharp, crisp
corners and edges.
37