So I had all of the parts ready for glue-up, the clamps were in reasonable shape, and I had the time this morning. It was time to glue and assemble.
I decided that I’d use my Workmate as an assembly table again, but that I wouldn’t use its jaws as a clamp (because I figured that the till would be too wide. So to start, I cleared it and pulled it to the center of the shop (where I would have access to all sides), and laid out the clamps set to their approximate settings:
I put wooden pads (made from the tenon waste of the shoe rack project) on the big clamp pads and between the pins on the tail side of the dovetails where the other clamps would go. Magic tape was my weapon of choice here, since I figured that the bond only had to last for less than a half-hour.
So far, so good. I laid out all of the parts in order (right side as step one, then the bottom, rear and front stretchers, then finally the left side would be banged into those pieces all at once). I decided that it was time to go.
Applying the glue and putting the pieces together wasn’t so bad, though I almost forgot to put in the front stretcher, I got everything together to a certain degree.
Then I moved it to the Workmate and put on the clamps. It was a little quirky, and of course I felt like I could have used a few more clamps, but it all went fine and everything drew up well.
At this point, it was time to drive in the little wedges on the through tenons. At first, it went just fine–I used the strange plastic-faced hammer that I use as a plane hammer (it has a specific purpose, but I don’t know what it is). It was kind of fun to bang those little things in, and they seemed to be holding up fine despite some of them having checks. Thump, thump, klonk. I had glue all over my fingers, but I was making good progress.
Halfway through this process, I realized that I was in trouble. You see, despite having a math degree, it seems that I still don’t know how to count. Remember how I said I needed ten wedges and made thirteen? From where did I get that number? There were four stretchers, with two tenons each, two wedge kerfs per tenon. 4 x 2 x 2 = 16, not 10. I should have made closer to 20 wedges.
Remember also how it took me a stupidly long time to make those? How could I possibly make three more in the limited amount of time I had? (Remember that I’m using liquid hide glue here!) Well, I still had some wide wedges that were in a reject pile. I decided to grab a chisel and chop straight down on these “rejects” at the proper width and hope that the checks and grain wouldn’t make me pay.
The results weren’t exactly perfect, but in a minute, I had made three wedges that would fit, and that’s what I needed. I banged those in, looked over the joints, checked stuff for square, and then started to take pictures.
It would have been better if I would have had a clamp for that center dovetail, but I don’t have one. Perhaps a really big block as part of the cauls.
I found a check in the upper left corner (in the preceding photo, it’s on the right side at the bottom). Oh, drat it. It was a problem I was fearing somewhat, and I don’t recall it being there before. I may have accidentally banged up that corner when I was attaching the left side. It doesn’t make any difference as far as the functionality is concerned, and in fact, it’s likely that no one will even see it (it’s on the far side of the till), but I wish I’d been a little more careful. Actually, what I wish the most is that I could find out when it happened.
Now the glue is curing, and I’m waiting for the final steps, which will be to level and plane off the joints, insert the blade rests, hang it up, and put some saws in there. I will not apply any finish to the till, at least for the moment. This is one of those projects that needs to be complete.