| 6) Now that you have the groove cut it's time to
cut the plywood. You will need a piece of furniture grade plywood approximately
1/4"x11 1/2"x19". In our clock we used Lauan plywood.
The plywood is to be cut slightly smaller than the inside of the grove. This will allow
for wood movement by the surrounding frame and inaccuracy in cutting and alignment. Note:
When we glue up the clock we do not glue the back in place. It should fit tight enough so
that this is not needed. 7) After you have the plywood cut you will
need to slightly round the corners so it will fit into the slot. This is because the
groove cut by the router is rounded in the corners. Test the fit and make adjustments as
needed. It should be a little loose to allow for movement, but firm enough that it will
not move on its own.
8) Once you are satisfied with the fit remove the plywood and
stain it with a black die or stain. (We used Minwax 2918 Ebony) The plywood might need 3-4
coats to achieve the desired results. Before you apply the stain, sand the plywood to
remove any rough spots.
We felt the black added a nice contrast to the color of the Brazilian Cherry and
highlighted the polished brass pendulum. The color you choose will depend on personal
preferences and the wood you selected for your plans. (See page 7 for suppliers)
9) We are now going to make the molding. For this we will need a piece
of stock approximately 11/2"x3"x27" thick. If you
can't find a piece this thick you can make it, we did with this clock.
To make the stock we will glue together two smaller pieces. The resulting piece will be
just as strong as a solid board.
A) Cut two pieces of 3/4" wood to
approximately 3"x27". The two pieces should be the same color, shade, and grain
pattern.
B) Sand, scrape, and smooth the surfaces of the two pieces and then clean
them with denatured alcohol to remove any sawdust or oils.
C) Spread a thin layer of glue across the surface and clamp firmly.
D) After the pieces have dried, unclamp and scrape off any glue that
dripped.
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