Shawn Pixley

After I get the concepts more or less set, I start to think practical. The first thing do (usually mentally), is figure out a draft sequence of operations. Here is my initial concept for this project.

Initial sequence thoughts

1. Legs Bandsaw curve & retape
2. Legs cut top angle
3. Legs Cut slot for bridle joint
4. Legs bandsaw taper & retape
5. Arc cut bridle joint dado
6. Arc bandsaw curve and retape
7. Arc taper ends
8. Arc & Legs router trim to templates
9. (end joint fabrication)
10. Remove offcuts
11. Legs cut stretcher mortises
12. Arc and Legs Round over 1/8" edges
13. Inlay arc (as desired)
14. Stretcher fabricate
15. Dry fit
16. While clamped, mark legs for trimming bottom
17. While clamped, measure and mark for bottom shelf as necessary
18. Template bottom shelf
19. Cut mortises in legs for bottom shelf
20. Test fit and fabricate bottom shelf
21. Dry fit assembly
22. Add stringing to "feet" (inlay?)
23. Glue up frame assembly
24. Pin bridle joint
25. Trim and round over leg tops
26. Mock up top?
27. End joint mortise in arc
28. Fabricate facet mounts (prongs) square with joint (without seat for facet)
29. Test fit
30. From template cut birds mouth and seat in prong (match arc of top)
31. Test fit top
32. Shape facet prongs
33. Test fit and sand prior to glue up
34. Mask off joints
35. Finish assembly pieces
36. Assemble and glue prongs and Arc together (hide glue for future prong removal)

After this is done, I create my template for the curves. I used 1/4 birch ply this time. I managed to delete the pictures I took of template making and layout making. The templates are very straight forward. With the layout, I try to be very precise and anticipate build issues. I find with curves, once things become round some tasks get inordinately difficult without building jigs. (I hate building jigs). I glued up poplar for the prototype and jointed it when dry. Layout on the stock the pieces to be cut, in this case a long leg and the arc. Due to the number of steps, I printed out a copy of the sequence of operations to take notes on while I am fabricating.

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There are four things I am looking to explore with the prototype build.

1. Tall vs short table (overnight I came to the conclusion, "why choose?" So I think I will be building one of each.)
2. Leg dimension and how it intersects the Arc (Equally proud front and back, Flush with the back, More proud front than back)
3. Verify sequence of operations
4. Validate construction methods on cheap materials before wasting good lumber

I found several improvements in the sequence of operations. Unfortunately, I also realized the prong joint to the arc was going to be more difficult than I thought initially. I punted on that for now. I will draw it out full size (using my template of course) to figure out just how I want to do it. I have an easy solution, but I think it will detract from the very "finished" aesthetic I am trying to craft here. More later...

I decided that equally proud front and back wasn't working for me to I mocked up the two different joints on ether end of the Arc.

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I am out of picture space on this post, so the next will be the prototype reveal.