Classic Writing Desk
Legs
Quantity: 4
Final Dimensions: 2” x 2” x 30 1/8”
Material used: 1 1/16” solid oak
Steps:
1. Select stock that will yield several pieces 2 ¼” wide.
2. Joint one edge
3. Rip cut 8 pieces to 2 ¼” wide on table saw
4. Cross-cut to rough length of 31” on miter saw
5. Match 4 pairs
6. Glue and clamp leg pairs face grain to face grain; let dry overnight
7. Scrape excess glue
8. Joint one of the glued edges on the jointer
9. Rip to 2 1/8” on table saw (place jointed edge against rip fence!)
Now each leg is 2 1/8” x 2 1/8” square
10. Surface plane legs to 2” x 2” square; plane all 4 edges of
each leg – 1 pass on each edge
11. Cross-cut 1 end square
12. Cross-cut opposite end to 30 1/8”
13. OPTIONAL: taper legs with taper jig as demonstrated
14. If you are not tapering the legs, rout chamfers, roundovers, or coves on each leg – stop each routed edge 6” from the top of the legs
15. Sand legs thoroughly
16. Using the mortise layout jig, mark 2 mortises per leg. Make sure the mortises are at the top of the leg and that they are on adjoining edges.
17. At the mortising machine, cut ¼” x 3 ½” mortises, ¾” deep
18. Sand all pencil marks and burn marks, bundle the legs together, and store. Make sure your name is on each leg
Apron Boards
Quantity: 4 total
Final Dimensions: Qty. 1 - Front Apron ¾” x 4 3/16” x 31 ¾”
Qty. 1 - Back Apron ¾” x 4” x 31 ¾”
Qty. 2 - Side Apron ¾” x 4” x 16 ¾”
Material used: ¾” solid oak (EXCEPT front apron from 1 1/16” stock)
Steps:
1. Select stock to complete pieces – try to get several apron boards from 1 piece of stock. MINIMIZE WASTE!
2. Joint 1 edge of all 4 boards
3. IMPORTANT: Set 1 long piece aside as front (4 3/16 wide”)
4. Rip cut 3 apron boards to 4” wide EXCEPT FRONT APRON!
5. Now, rip the Front Apron to 4 3/16” wide – SET ASIDE
6. Cross-cut 1 end square on all 4 pieces
7. Cross-cut 2 side aprons to 16 ¾”
8. Cross-cut back apron to 31 ¾”
9. Cross-cut FRONT APRON to 32”
10. On FRONT APRON, complete 4 cuts for drawer opening. Rip 1” off the top edge and bottom edge of the apron. Then, with the remaining middle piece (should be 2” wide), cross-cut a 6” piece off each end. Glue and clamp these 4 pieces back together – remember to MATCH THE GRAIN
11. Next class - surface plane front apron to ¾” thick – plane both faces
12. Now, cross-cut 1 end square and then cut FRONT APRON to final
length - 31 ¾”
13. Take all 4 pieces to the dado saw, cut ¼” x 3 ½” tenons, ¾” long.
14. Test the fit of the tenons in your mortises
15. Dry assemble table to check fit.
MAJOR ASSEMBLY Table will be glued and clamped in several steps
1. Glue back apron to 2 legs and clamp – check for square
2. Glue front apron to the other 2 legs and clamp – check for square
3. Once dry, glue two previous assemblies together with the side aprons and clamp – check for square
REMEMBER: Spread glue in mortises AND on tenons
Drawer Guides – 2 “L” Guides
Quantity: 4 total pieces
Final Dimensions: Qty. 2 - ¾” x 2” x 18”
Qty. 2 - ¾” x 2 ¾ ” x 18”
Material Used: Use scrap ¾” plywood
Steps:
1. Locate scrap ¾” plywood at least 18” long.
2. Rip cut 2 pieces to 2” wide on the table saw
3. Rip cut 2 pieces to 2 ¾” wide on the table saw
4. Cross-cut all 4 pieces to 18” long
5. Align 2 ¾” piece on top of 2” piece - glue and nail drawer guides together with 1 ½” brads. This should form a 2” x 2” inner corner.
6. Allow glue to dry
7. Carefully measure inside depth of table and cross-cut drawer guides to fit on each side of drawer opening (roughly 17”)
Nailing Blocks
Quantity: 4
Final Dimensions: ¾” x 2 ¾” x 4”
Material Used: Use scrap ¾” plywood
Steps:
1. Locate enough ¾” scrap plywood stock to complete all 4
2. Rip to 2 ¾” wide
3. Cross-cut to 4” long
4. Make layout line on front and back aprons per demonstration;
these lines will indicate the exact location of the nailing blocks
5. Glue and nail these blocks to the inside of the aprons with 1 ¼” brads – do not use longer brads which will emerge out the other side
ASSEMBLY – Glue and nail drawer guides to nailing blocks with 1 ½”
brads
MAKE SURE TO LINE UP TOP EDGES (FLUSH
WITH EACH OTHER)
Drawer Pieces
Quantity: 4
Final Dimensions: Qty. 2 sides – 1/2” x 1 ¾” x 17 1/2”
Qty. 1 front – 1/2” x 1 ¾” x 19”
Qty. 1 back – 1/2” x 1 ¾” x 19”
Material used:½” Plywood (Birch or Oak ply depending on availability)
Steps:
1. Select ½” stock for drawer components
2. Using jointer, table saw, and miter saw, cut drawer parts to the dimensions listed above
3. Cut a ¼” deep x ¼” wide dado on all four drawer pieces for the bottom panel. This dado should be ¼” from the bottom edge of the drawer pieces
4. Cut a ¼” deep x ¼” wide rabbets on the ends of the side pieces as demonstrated
5. Dry assemble the drawer and check the measurement for the bottom panel – the bottom panel should be 16 15/16” W x 18 15/16” L
6. Cut the bottom panel to size (make sure all edges are square) and dry assemble the drawer around the bottom panel (best face up). Check the fit and slide of the drawer in its opening
7. Sand all parts of the drawer before assembly
8. Assemble the drawer with glue and 1” brads.
9. Ease the top edges of the drawer with a router or sandpaper as demonstrated
Drawer Front
Quantity: 1
Final Dimensions: 5/8” x 2 ½” x 21”
Material Used: scrap oak
Steps:
1. Locate a piece of stock to complete the drawer front
2. Surface plane to 5/8”
3. Joint one edge, rip to 2 ½” wide
4. Cross-cut 1 end square, cross-cut opposite end to length (21”)
5. Shape front face with 3/8” roundover bit in router – use router pad, overhang the edge of the workbench, and avoid burning
6. Sand drawer front and edges prior to assembly
7. Center the drawer front on the drawer
8. Attach from the inside with glue and nails
Top
Quantity: 1
Final Dimensions: 7/8” x 21” wide x 36” long
Material used: 1” solid oak
Steps:
1. Select stock for glue-up. Glue-up should be larger than the final size of the top (Rough dimensions: 22” wide x 37” long)
2. Joint all mating edges, reverse annual rings – use at least 4 bar clamps
3. When glue has cured, joint one edge of the panel
4. Rip the panel to final width (21”) on table saw – place cut-off in scrap area
5. Surface plane the panel to final thickness of 7/8” (for “thinner” top, surface plane to 11/16”)
a. Only moving the handle 1/2 turn per pass to remove 1/32”
6. Cross-cut 1 end square
7. Cross-cut the opposite end of the panel to a final length of 36”
8. Shape or router all 4 edges of the top with the bit of your choice
9. Sand top thoroughly
10. Drill 6 recess holes (3/4 dia.) on tops of aprons for Figure-8 fasteners
11. Attach six Figure-8 fasteners to aprons with ¾” long screws
12. Place top upside down on bench, flip table upside down onto top, center the top, and attach with 6 ¾” long screws
Final Steps
1. Sand project thoroughly with 220 grit sandpaper
2. Stain all project components including drawer front – do not stain the drawer itself – only the drawer front
3. Apply colored wood putty to nail holes, cracks, imperfections, etc.
4. Apply 2 coats of lacquer to all pieces – sand with 600 grit between coats
5. Attach drawer pull as instructed
a. Place masking tape on drawer front
b. Find center of drawer front
c. Go out horizontally 1 ½” each direction from the center point
d. Make a mark (marks should be 3” apart) and drill through 3/16” or 13/64” holes
e. Attach handle with 8-32 x 1 ½” long screws and screwdriver
CONGRATULATIONS!