(upbeat jazz music)
Marc: Now it's time to work on the headboard.
The raised panel will be made from 2
beautiful, 4 quarter, wenge boards.
After milling, the boards are glued together,
smoothed with a number 80 cabinet scraper,
and sanded with the drum sander.
To create the raised panel profile,
I'm gonna remove the back cutter
from a standard raised panel bit
and route the profile at the router table.
That's a big bite to take in 1 shot
so I work my way to the final profile
over the course of several passes.
The profile is then sanded thoroughly.
Now for the headboard frame.
The long headboard pieces are cut to length
using the cross cut sled.
I showed you the details of this set up
in episode 190, Frankensled.
The shorter vertical headboard pieces
are also cut at the table saw.
The lower half of the headboard frame
is assembled using dominoes,
specifically these big 14 millimeter dominoes
made using the domino XL.
The small, middle support leg
gets the same joinery.
A little glue on each joint,
a little help from a dead blow hammer,
and the lower frame is assembled.
The upper frame pieces
need a groove for the wenge panel.
The stopped grooves are cut with a router.
And the through grooves are cut
with the dado stack at the table saw.
Like the lower frame,
the top frame is held together with dominoes.
Before final assembly,
I'm inserting scrape pieces of foam
that will prevent the panel from rattling
while also allowing for expansion.
Assembly involves dropping the wenge panel in place
and then adding the side pieces.
I use some long clamps to bring everything together.
A little bit of squeeze out is always a good thing.
And the piece is left to dry overnight.
Before assembling the top and bottom halves
of the headboard, we need to cut the mortises
which go on both of the outside legs.
Man:So it took a total of 4 passes but we got it
so all I need to do is square this up with a chisel
but while I'm in router mode,
I'm gonna go to the foot board.
Then we'll chisel everything
when it's all said and done.
Voiceover:Now with my track saw set to 10 degrees,
I'm cutting the long bevel on both
the bottom headboard piece
and the top headboard piece.
A 10 degree bevel on both pieces
yields a 20 degree back slant overall.
I need all the alignment help that I can get
so once again, I use dominoes.
This is one of the trickiest glue ups
I've ever done.
But with the aid of angled, clamping [calls],
glued to the wood surface with CA glue,
I can effectively pull the pieces together.
Because I need some extra working time,
I'm using epoxy as the primary adhesive.
Man:Alright.
Well, I feel a little bit better
now that this part is over.
Voiceover:The next day,
the blocks are removed with a hammer
and because the 2 x 4 material used for the [calls]
is much softer than the bubinga,
the bubinga is unharmed.
The excess glue is scraped off
and then sanded away.
While the headboard is on the bench,
I give the entire thing a nice sanding
before calling it done.
Voiceover:Next time on The Wood Whisperer.
(upbeat jazz music)