As mentioned, this project falls into the realm of mass production but still is enjoyable to me.  What’s that saying about if you enjoy what you’re doing it really isn’t work?  That’s how I feel about this because you do have to keep on your toes, sometimes repetitious processes lend themselves to mistakes more so than a singular complicated process.  In any case, thought I’d share the progress so far and ……. for those inquiring minds that want to know these things there is approximately 6.45 hours of actual work time into this project.

Here’s the beginning and ending stages of the work so far — Basswood from Woodworkers Source was of great quality.

20 Board Feet of Basswood

60 Frame Pieces for Assembly

The first step was to rip those wide boards to 3″ width, they were 6′ long and right around 10″ wide.  Creating the profile required three separate set-ups on the router table plus a dado set up to create the rabbet.  Pieces were then cut to 11″ and 13″ and the outer edge was planed smooth while the coves were sanded by using a tadpole sander.  Here’s a collage to illustrate the process:

1.) Sight Edge

2.) Coves

3.) 15° Chamfer

4.) Rabbet

5.) Hand Work

After this work was complete the pieces were all mitered to the required size.  This was followed by cutting a slot for a #20 biscuit in each end.  Just curious, do any of you that use a biscuit joiner find that the biscuit is usually too tight?  I end up cutting the slot twice; for the second cut I increase the depth ever so slightly.  This allows for a bit of movement as the clamps are placed on the frame.

Mitering to Size

Biscuit Joiner

It’s always tricky cutting the biscuits on the left side of the frame, good thing I’m somewhat ambidextrous!  Looks like it’s time for glue ups!