Greene & Greene Thorsen Sideboard #7: Cloud Lifts and Square Plugs

  • Advertise with us
Blog entry by TungOil posted 03-13-2020 04:52 PM 888 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 6: Veneering the Panels Part 7 of Greene & Greene Thorsen Sideboard series Part 8: Carcass Assembly »

With my panel veneering completed, I move on to the detail work for the carcass.

Most of the edges get a 1/8” round over, so I handle those on the router table. Most of the rounding work can be completed with a standard router bit, but the slots in the lower stretchers are too narrow for the pilot bearing on a standard bit. For those, I switch to a special bit with a very small pilot bearing, as seen in this image.

The cloud lifts and slots on the lower stretchers require additional rounding over with rasps to get the final shape. I start with the stretcher with just the 1/8” round over from the router table.

I then work the ends of the two slots and the ‘bump’ on the cloud lift with rasps to add a more rounded shape to these areas, as on the original G&G piece. I blend these features into the surrounding area in an almost worn look.

The change is subtle but it makes a big difference in the finished piece.

The legs require a number of square holes to accept ebony plugs. I mark the plug locations with the carcass dry assembled to be sure I don’t make any layout mistakes. I then disassemble the carcass and pre-drill for the Veritas square chisel and cut the square plug holes. To align the chisel in the hole, I pass a steel dowel pin through the center of the square chisel and into the hole, then I square up the chisel to the side of the part using a saddle square. Once squared to my liking, I gently press the 4 points of the square chisel into the leg, remove the dowel pin and saddle square and hammer out the square hole.

The bottoms of the legs get some additional rounding with rasps.

Next Steps: finish sanding of the carcass parts and assembly.

-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"

3 comments so far

View splintergroup's profile


5864 posts in 2467 days

#1 posted 03-13-2020 06:50 PM

Is that the Amana bit?

I love that bit for producing a true 1/8” radius on inside corners, saves a bunch of hand work.

I finally purchased a 4-jaw chuck I can fit in my DP, great way to hold those ebony sticks and form the plugs with sanding pads.

Looking great as always!

View TungOil's profile


1384 posts in 1740 days

#2 posted 03-13-2020 06:54 PM

Yes, I think it is the Amana bit. I’ve had it a few years so I don’t recall exactly. I do remember there were not many choices when I bought it.

The four jaw Chuck makes forming the plugs much easier.

-- The optimist says "the glass is half full". The pessimist says "the glass is half empty". The engineer says "the glass is twice as big as it needs to be"

View EarlS's profile


4754 posts in 3593 days

#3 posted 03-14-2020 01:59 PM

I have a couple of bits like that from MLCS

Keep an eye on the brass bushing. It likes to ride up and can come off.

Thanks for the tip for cutting out the holes for the square plugs. I’ve always just eyeballed it to verying degrees of success (or not).

I’m feeling your pain on a long tedious project – 6 sets of closet cabinets, 5 drawers each, and the rest of the associated built-in closet stuff.

-- Earl "I'm a pessamist - generally that increases the chance that things will turn out better than expected"

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics