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The next step
is for Bethany to layout the top and bottom from the wood blank. Per the instructions, she
marks an "X" across the wood so that she can keep the grain matched as she cuts
them apart. She also marks them "A" and "B" — just as in the
instructions.
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She now cuts them to the widths
required in the book. The "A" piece is cut to 2 5/8" width and the
"B" to 2 7/8".
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Her next operation is back at the router
table. The bullnose bit is still installed and is now used for rounding over some of the
edges.
She starts by rounding over both ends of the "B" piece. These first
cuts are done with the piece flat on the table.
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Now with the "X" mark facing
away from the fence, and the "B" towards the infeed side, she shows how she will
make the next cut standing the "B" piece vertically against the fence.
Marking the pieces at the beginning makes it extremely easy to follow what
otherwise might be confusing directions. All she had to do was to orient each piece as it
showed in the instructions.
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Here, she is making the vertical cut.
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She now moves to shaping the
"A" piece. For this piece, she will shape only one edge—the edge that the
"X" is marked. The first cut is made with the piece flat on the table.
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Now, she prepares to make the vertical
cut, as she did with the "B" piece, but again only on the one edge.
As before, she lines up the stock just as it shows in the instructions.
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Bethany removed the auxiliary fence and
installs a 1/2" straight bit.
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She uses the handy Incra Gauge to set
the router bit height at 1/4".
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She zeros the bit to the fence and
slides the inch scale to "0".
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Now she can move the fence
to 3/8" and use the push block and make the first cut on the "B" piece.
There will be a series of cuts to remove quite a bit of material on the inside of the
case. (By the way, this was a mistake—the instructions call for the use of a standard
padded push block. In using the block as shown, she is cutting away a portion of the
block.)
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Bethany has switched to using a
different push stick. This, in conjunction with a padded hold down block, allows her to
make the passes and still maintain control of the piece.
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