preparation of wood: from rough to smooth, straight and square paul...
TRANSCRIPT
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Preparation of Wood: From Rough to Smooth, Straight and Square
Paul Roberts
Wood Preparation 8.4.2017
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Wood Preparation 8.4.2017
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• Accurate machining fundamental to quality of woodworking
• Rough timber-defects flat, square & straight
• Rough timber cut/planed to size & also to be stable
Wood Preparation 8.4.2017
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• The Technical Note, 16 FWW References, Presentation available electronically after the Workshop
• Comments and queries appreciated during the presentation
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1. Purpose of the document 2. Quantification of wood requirements 3. Purchasing wood 4. Tools and equipment 5. Rough machining 6. Resawing 7. Final machining 8. Safety considerations 9. Conclusion 10.
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• WWAP Mentorship scheme
• Applicable to hand or machine wood preparation
• More than one way of doing work
• Technical Note to be on website
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2.1 Design plans
2.2 Cut-list
2.3 Wood defects
2.4 Rough dimensioning
2.5 Wastage
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• Accurate design plans
• Aesthetics/ergonomics
• Models and mock-ups
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• Own plans (metric units-mm)
• Bought plans (imperial units)
• Plans hand drawn on computer software (AutoCAD, SketchUp)
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Wood Preparation 8.4.2017
Hand drawn plan of Morris chair
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Wood Preparation 8.4.2017
Morris chair components
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• Cut-list needed for purchase of wood and its machining in components
• Excel spreadsheet or design software
• Preparation of wood in two stages (reflect in cut-list):
• Rough machining
• Final Machining
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Wood Preparation 8.4.2017
Typical cut-list
Typical Cut-list
Item
ID
Part Name Wood Final Dimensions Rough Dimensions Remarks
No T W L No T W L
A
B
C
ID=Item Identification No=Number of items T=Thickness W=Width L=Length
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Wood Preparation 8.4.2017
CUT-LIST PROJECT: MORRIS CHAIR (2 OFF) DATE: 15.3.2017
Final Dimensions (mm) Rough dimensions (mm)
Item ID
Part Name Wood No T W L No T W L ΣL Plank Remarks Wood Volume
m3
A Front Leg Minger 4 60.0 60.0 630 12 22 65 650 7,800 Laminate to quartersawn 0.01115400
B Back Leg Minger 4 60.0 60.0 630 12 22 65 650 7,800 Laminate to quartersawn. Same as A initially 0.01115400
C Front Stretcher Minger 2 30.0 171.0 594 3 22 180 630 1,890 Resaw and laminate 0.00748440
D Back Stretcher Minger 2 30.0 100.0 594 3 22 110 630 1,890 Resaw and laminate 0.00457380
E Lower Rail Minger 4 30.0 180.0 614 6 22 190 650 3,900 Resaw and laminate 0.01630200
F Upper Rail Minger 4 30.0 100.0 614 6 22 110 650 3,900 Resaw and laminate 0.00943800
G Side Slat Minger 16 20.0 65.0 208 8 22 70 450 3,600 2 per plank as short 0.00554400
H Arm Minger 4 25.0 120.0 900 8 22 130 1000 8,000 Four laminates and glued over a bowed jig 0.02288000
I Cleat Minger 4 20.0 25.0 530 4 22 30 600 2,400 0.00158400
J Corbel-Front Minger 4 30.0 40.0 450 6 22 50 500 3,000 Resaw and laminate 0.00330000
K Corbel-Back Minger 4 30.0 40.0 380 6 22 50 450 2,700 Resaw and laminate. Nest J&K to save wood 0.00297000
L Backrest Post Minger 4 30.0 45.0 750 6 22 50 800 4,800 Resaw and laminate. Nest J&K to save wood 0.00528000
M Top Back Slat Minger 2 40.0 100.0 470 4 22 110 520 2,080 Shaped 0.00503360
N Back Slat Minger 8 40.0 65.0 470 16 22 70 520 8,320 Shaped 0.01281280
O Pivot Pin White oak 4 25.0 25.0 120 1 30 30 550 550 25 dia 0.00049500
P Support Pin White oak 4 25.0 25.0 107 1 30 30 500 500 25 dia 0.00045000
Q Spacer White oak 4 8.0 40.0 40 1 4 50 600 600 Laminate like ply to prevent cracking. 40 dia 0.00012000
V Veneer-Legs Minger 8 3.0 60.0 595 8 5 70 670 5,360 595 for A and 530 continuous for B 0.00187600
W Seat Frame-F&B Minger 4 22.0 70.0 555 4 22 75 570 2280 Measure chair when assembled before sizing frame 0.00376200
X Seat Frame-Sides Minger 4 22.0 70.0 605 4 22 75 620 2480 0.00409200
Webbing 50.0 9 24.2
Webbing clips 40 TOTAL Volume (m3) 0.12245160
Note: Rough Planed Minger stock is about 22 thick
Length (m) of 22x230
Note final thicknesses may have to be reduced by about 1 to 2 mm. Measure up and decide when final planing. Compare also with Dries' dimensions in his cut-list.
Example of a cut-list
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• Defects-harvesting & drying
• Study wood carefully to overcome defects
• Major defects and remedial measures
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Bow
Bow occurs along the length of a board on the face side. If the bow is severe it
is best to cut the board into smaller sections before machining
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Cup Cup occurs across the face of a
board. If lumber is badly cupped, rip it into narrower sections; you
will end up with thicker stock after edge-jointing and planing
Wood Preparation 8.4.2017
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Twist
Lumber with a slight twist will give you fits if not removed prior to cutting joints or gluing panels together. If it is severely twisted, cut lumber into shorter and/or
narrower sections for better yield.
Wood Preparation 8.4.2017
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Crook
Crook is a bow along the edge. You will end up with waste along both edges when ripping it straight and parallel
Wood Preparation 8.4.2017
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• Study the wood carefully
• Notes to optimise wood selection
• Annular ring orientation
Wood Preparation 8.4.2017
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• Wood movements after first machining due to internal stresses
• Wood defects (cup, crook, bow etc)
• Machine eg snipe
• Wood characteristics
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Typical allowances
• Thickness + 3 mm
• Width +5-10 mm + saw kerf if ripped
• Length Remove end splits + 50-100 mm for planer snipe
Wood Preparation 8.4.2017
Final Dimensions (mm) Rough dimensions (mm)
Item ID
Part Name Wood No T W L No T W L ΣL
A Front Leg Minger 4 60.0 60.0 630 12 22 65 650 7,800
B Back Leg Minger 4 60.0 60.0 630 12 22 65 650 7,800
C Front Stretcher Minger 2 30.0 171.0 594 3 22 180 630 1,890
D Back Stretcher Minger 2 30.0 100.0 594 3 22 110 630 1,890
E Lower Rail Minger 4 30.0 180.0 614 6 22 190 650 3,900
F Upper Rail Minger 4 30.0 100.0 614 6 22 110 650 3,900
G Side Slat Minger 16 20.0 65.0 208 8 22 70 450 3,600
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• Allowance for wastage of stock when procuring timber due to errors or defects in planks, grain colour
• Rule of thumb: Allow about 10-15% extra for wastage
Wood Preparation 8.4.2017
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• The selection of suitable wood for the project requires a good knowledge about wood, its properties and grain characteristics.
• The types of timber cuts and the categories relate to the angle of the annular rings compared to the face of the plank.
Wood Preparation 8.4.2017
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• Select planks at the timber yard yourself rather than simply ordering a required quantity;
• Inspect planks for problem areas;
• Some wood suppliers may allow you to plane a little area to inspect the grain. Take a small plane along and ask permission!
Wood Preparation 8.4.2017
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Wood Preparation 8.4.2017
Flat-sawn
Rift-sawn Rings 30⁰ to 60⁰
Quarter-sawn Rings 60⁰-90⁰
After Ref [5]
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Tools:
• Squares;
• Straight edges;
• Vernier callipers and carpenter rule/tape;
• Winding sticks to test twist;
• Marking items (permanent markers, pencils and chalk).
Wood Preparation 8.4.2017
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Equipment
• Planer/thicknesser (hand planes)
• Circular saw/s
• Bandsaw
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Equipment
• Selection of correct blades
• Blade sharpness
Wood Preparation 8.4.2017
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• Shorter lengths (min 200-300mm)
• Trim rough ends
• Inspect wood-ID number on ends
Wood Preparation 8.4.2017
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• Inspect wood before marking
• No nails, staples, dirt (carpet strips)
• Badly cupped-rip & reglue
• Keep marking of items
Wood Preparation 8.4.2017
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• Decide on the arrangement of the various items from each plank
• Cross-cut the plank using a suitable saw
• Mark the ends with the ID number
Wood Preparation 8.4.2017
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• Gauge wood-straight edge
• Surface cupped surface first
• Grain direction-change surfacing direction if necessary after inspection
• Mark grain direction-my convention
Wood Preparation 8.4.2017
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• Surface at least 75% of area
• Thickness of cut-wood type?
• Depth of cut 0.5-1.0 mm
Wood Preparation 8.4.2017
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• Measure wood thickness
• Sort in categories of 1 mm;
• Sort orientation for the thicknesser;
Wood Preparation 8.4.2017
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• Start with thickest & machine till all can be processed
• Thickness to rough thickness • While thicknessing can turn the plank
over once a plane upper surface achieved • Leave the planed stock for several days
for initial stresses to relax & wood to acclimatise to ambient moisture content before undertaking the final machining
• Monitor any movements/deformations
Wood Preparation 8.4.2017
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Various approaches
• Jointer (surfacing table)
• Portable saw and guide
• Router and guide
• Long sled and a table saw
• Table saw after initial edge
Wood Preparation 8.4.2017
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• Need for resawing • Circular saw or bandsaw • A sharp & preferably a coarse (3 tpi) wide
blade • Tune up & adjust the saw for proper guide
clearance, squareness of the blade to the table & use a high blade tension
• Use suitable guides/fences • Cut slowly and do not strain the bandsaw • Cut boards 2-3 mm thicker than needed
Wood Preparation 8.4.2017
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Wood Preparation 8.4.2017
Veneer 3 mm thick
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Wood Preparation 8.4.2017
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• Thinner cuts than rough machining
• Sharp blades
• Check straightness/flatness & resurface/thickness as necessary to final dimensions
• Edge joining-reference alternate faces
Wood Preparation 8.4.2017
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• Do not cut items to final length until just before the fitting & jointing process to ensure a tight fit
• Cross-cut items accurately to final lengths which is part of the jointing process
• Jointing should be undertaken as soon as possible after final machining while the stock is still square and flat (final machining in phases?) Depends on wood stability
Wood Preparation 8.4.2017
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• Use push sticks as necessary • Do not look into the thicknesser slot • Use sharp blades • Wax on jointer/thicknesser surfaces
reduce drag forces • Care must be taken with the use of
gloves which could be worn to obviate splinters and cuts with rough timber. The gloves, if used, should be tight-fitting
Wood Preparation 8.4.2017
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• Dust protection
• Splitter for ripping to prevent sawn items from binding on the blade
• Eye/ear protection
• Suitable safety shoes, particularly when handling large and heavy planks
Wood Preparation 8.4.2017
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Wood Preparation 8.4.2017
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Many consider wood preparation to be hard work & boring
BUT It provides much reward in: • Revealing beautiful grain; • Achieving a sense of achievement when
overcoming defects and internal stresses in the wood and to create stable components;
• Providing a great understanding and love of wood and its properties.
Wood Preparation 8.4.2017