Now we do the crest rails.
The first thing we do is to prepare the blanks which are about 65" by 6 1/2".
The crest rails will be 60" wide but we will need some extra material on the ends
to make jigs to help us drill dowell rod holes. So we will make then 65 " long for now.
As you can see in the picture above, there are a lot of cuts. Once done we throw away the
triangular waste pieces to be left with this.
So if we clamp them the final look will be this.
I used biscuits to join the pieces. I cut slots in all three parts and then glued them together.
The biscuits look like this prior to gluing.
Then I use a lot of clamps -- I actually need more!! That is on my wish list I think.
Next is the cove cut which means you run the glued assembly through the table saw
at an angle to create a dished out curve. Here is the plan.
Here is a picture of this setup.
and here is a close up using a practice cut to show you what I mean. You can see how
the angled cut will cut out the dish.
And here is a closeup of how I set the guide fence for this cut using the scraps with the marked distances.
And finally, here is the finished cut!
Next cut a dado down the center of one edge. I used a palm router with an edge guide
and made a lot of passes to get to the depth I wanted.
Now flip the assembly over. It is not round at all on the top at this point. So I started to work
on removing material using my handplanes. It starts looking like this.
and eventually looks like this.
I fined tuned the rounding using a small microplaner.
Here are the two rounded crest rails next to one of the cross rails. They have now been cut to their 60" size.
Next the dowel rod work.
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