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9 foot tall 3-level cross for Baptist Church

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Project by DaleMaley posted 01-14-2019 02:05 PM 769 views 0 times favorited 8 comments Add to Favorites Watch

Last summer, a friend of mine asked me to design and build a 9 foot tall wooden cross for his church. He wanted the cross to be 3 levels, or 3 crosses stacked on top of each other.

The back cross was the biggest and the heaviest. I built all the crosses in my basement shop, then hauled them up the stairs to my garage for final assembly. I could not carry the back cross, I had to first carry up the huge vertical section, then make 2 more trips with the horizontal arms.

The front and back crosses are pine….........the middle cross is reclaimed walnut.

I made the crosses using box type construction, versus solid wood. This saves wood, and makes the cross a lot lighter.

I have said it so many times, that my wife even knows my saying, “A woodworker can never have too many clamps”............and this was definitely one of those projects!

I used the biggest mortise and tenon joints I have ever done…........to join the horizontal arms to their vertical members. At final assembly, I used the offset peg method to draw the horizontal arms as close as possible to their vertical elements….......in the mortise and tenon joints.

My friend helped me deliver the un-stained 3 crosses to the church several months ago. Other volunteers changed the back of the church to wood, stained my cross, added lighting, etc. They completed the project yesterday and had their 1st church services with the new design.

You can see more details at my woodworking web site here.

Thanks!

-- Dale, Illinois, http://dalemaley.webs.com/





8 comments so far

View Steve's profile

Steve

1648 posts in 1149 days


#1 posted 01-14-2019 03:21 PM

I’m always in awe at the scope of your projects.

How did you attach the three crosses together? Did I read that you just screwed them to each other from the back?

View GR8HUNTER's profile

GR8HUNTER

6710 posts in 1279 days


#2 posted 01-14-2019 03:21 PM

I kind of would love to know how they hung this beast up GREAT JOB :<))
Also love how top one stands proud of bottom one

-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View Orvile Baker's profile

Orvile Baker

253 posts in 1245 days


#3 posted 01-14-2019 03:22 PM

Very nice.

-- Bud Baker , Ojibwa, WI. http://papabudswoodtoys.webs.com/

View DaleMaley's profile

DaleMaley

501 posts in 2803 days


#4 posted 01-14-2019 03:39 PM



I m always in awe at the scope of your projects.

How did you attach the three crosses together? Did I read that you just screwed them to each other from the back?

- Steve

When I delivered them to the church, we chose to transport the 3 crosses individually because of the weight. I instructed the other volunteers to screw the 3 levels together when they were ready (I think they used different color stains on the 3 levels, and it is easier to stain the crosses individually versus screwed together). Since I was not there, I don’t know for sure how they assembled the 3 levels together…...my guess is they screwed them.

thanks

-- Dale, Illinois, http://dalemaley.webs.com/

View DaleMaley's profile

DaleMaley

501 posts in 2803 days


#5 posted 01-14-2019 03:40 PM



I kind of would love to know how they hung this beast up GREAT JOB :<))
Also love how top one stands proud of bottom one

- GR8HUNTER

I am not sure how they hung the whole cross assembly either. Maybe I can tell when I stop in and see the finished project in person…....which I plan to do soon.

-- Dale, Illinois, http://dalemaley.webs.com/

View DaleMaley's profile

DaleMaley

501 posts in 2803 days


#6 posted 01-14-2019 03:44 PM



I m always in awe at the scope of your projects.

- Steve

The 22 foot diameter park gazebo, which had 497 pieces of wood…..........was probably the most difficult and largest project I have designed and built…......

-- Dale, Illinois, http://dalemaley.webs.com/

View dalepage's profile

dalepage

385 posts in 1407 days


#7 posted 01-15-2019 12:55 PM

Fine job, Dale. What is “offset peg method” you refer to in the glue-up?

-- Dale

View DaleMaley's profile

DaleMaley

501 posts in 2803 days


#8 posted 01-15-2019 01:03 PM


Fine job, Dale. What is “offset peg method” you refer to in the glue-up?

- dalepage

sorry, I should have explained that better….....

I wanted a method that would draw the horizontal arms as tight as possible against the vertical element. This draw bore method does this. I have some smaller mortise and tenons where I did this…...........and they are still tight after 20 years of service. This is the biggest mortise and tenon joint I ever built on this cross project…...but the draw bore method still worked very well.

I drilled blind holes from the back of the cross, because I did not want the pin holes to show in the front of the cross. You do have to be careful on blind pin holes….....that you do not hammer too hard on the pin and blow out the hole in the front (which I did on 1 pin).

-- Dale, Illinois, http://dalemaley.webs.com/

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