Missing Pieces:
When inspecting a new project clock it is not
uncommon to find that a piece of the wooden case
has gone missing. Usually, this is some type of curved molding that
is not an off-the-shelf item.
Custom moldings can be
produced by many custom cabinet shops, but the price for a small,
single piece as on a clock case will tend to be unusually expensive
simply because of the set up costs.
Many missing pieces can
be produced in the shop using commonly available tools. The
presentation that follows shows how one missing molding piece was
created using only a table saw and wood scrapers. |
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When a piece of molding is found to be missing, always check the
Surface to which it abutted. There is often a faded outline of the
original contour. This will be very helpful in creating a new piece. |
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A white lead pencil as is used in sewing is useful to drawing in the
missing contour so that it is more easily seen. |
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A piece of translucent plastic can be used to copy the contour and
make a template. |
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The contour is then
transferred to the end of a suitable piece of wood.
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It
is recommended that the contour be copied onto both sides of the
wood. |
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The table saw blade is adjusted to make cuts across the board up to
the height of the molding line. |
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It
takes a little time and patience, but a "stepped" cut out of the
molding shape can be easily achieved. |
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Final shaping up to the
line is done with sander and scrapers.
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A contour gage
comes in very handy for checking your work. |
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Sanding drums can
be used for initial shaping. |
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Check the progress
frequently.
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Traditional hand
shapers may appear out of date, but work very well for final contour
work. |
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Final shaping is
done using various grades of sand paper. |
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Once satisfied
with the final contour, the piece is ready for test
fitting and veneer. |
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When installed,
the contour can be checked against the original
"shadows" on the case pieces. |
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Veneer can be cut,
softened and pre-bent using your favorite
technique. |
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Clamping with
contour blocks or vacuum pressing can be used
to install the veneer. |
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The missing
molding with veneer............ |
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A little shellac
and the piece looks like the original. |
The number of
different contours that can be made using this technique is
essentially limitless. It is recommended
that a good quality "carbide" blade be used when cutting.
As with any power
tool, appropriate safety precautions should be taken. If you are
unfamiliar with power tool seek
assistance.
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