Princess Daybed for Daughter #3: Stock prep and mortising

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Blog entry by JohnMcClure posted 07-10-2018 12:24 PM 809 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 2: Drafting my plans - taking shape! Part 3 of Princess Daybed for Daughter series Part 4: Tenons! »

I picked up two douglas fir 4×4s and two SYP 2×10s.
One of those 2×10s contained three bottom rails (long back rail, two short side rails). The front rail is going to be thinner, 3/4”, to minimize shin-smashing risk; so it should be hardwood.
How about this, from the pile under the tarp?

You’ll see.
Once that’s planed down and the rotten section trimmed out, it looks like this:

Now I have a stack of boards cut to rough length, a bit overlong. It’s not the whole bed yet, but enough to get started working:

Next step is to resaw, joint, and plane the 4×4s down to 3×3:

These posts need grooves to hold the back and side panels, and mortises 1.75” deep to retain the rails.
I’ll groove on the router table, then deepen the ends to start the mortises as deep as the RT will allow:

One groove had awful tearout. The correct fix is to mill out the torn section, inlay identical wood, and re-mill the groove. But I’m in a hurry, and the project will be painted, so I quickly glued in some splinters and held the groove open with a piece of scrap. I’ll use filler before painting if required.

The RT could only mortise to about 3/4” deep, so I need an extra inch. Forstner bit on the drill press does most of the work, then a chisel cleans it up and squares the corners:

The mortises for the front rail are 3/4” wide (full width of stock). It turned out that forstner bit mortising is WAY easier in a 3/4” than 1/2”, as the ones pictured were, because of easier chip clearing. Or maybe it’s just my bits.
Pictures of those mortises (prettier) in the next entry, maybe.

A humorous parting note: my patented “Universal stock support for the drill press:”

Next step is to crosscut bottom all straight rails to length, lay out and cut the tenons, and groove said rails for the panels.
Step after that is to layout and cut the curved upper rails, then tenons and grooves.
After that, cut panels to fit within rails and posts.
Then add the decorative “M” and trim. Also need to put pegs in the joints for knockdown.

-- I'd rather be a hammer than a nail

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