1. Mantle Clock

2. Beginning Steps Cut 2 piece 20 x 5 to make the 2 sides and top/bottom Cut 1 10 ¾ and 1- 9 from each 20 piece. This will make a side and top or bottom Tape sides together so students will make a left and a right and not 2 lefts or 2 rights.

3. Trace pattern and cut curves Sand Curves on a spindle sander or a spindle sander attachment on the drill press.

4. Set Dado on the table to make the cross dado’s. ¾ dado 3/8 deep. – Make a jig for the table that will hold the sides as you cut the dado and the rabbet. This will speed up the process for making the side and will greatly reduce the number of student errors

5. Set Dado on the table to make the cross dado’s. ¾ dado 3/8 deep. – Make a jig for the table that will hold the sides as you cut the dado and the rabbet. This will speed up the process for making the side and will greatly reduce the number of student errors

6. Cutting the groove/dado On another table saw, set the blade height to be the same height as the dado set for the cross dado. Cut a groove* 2 ½ from the front edge of the project. Be sure to place the curves against the fence so the project will line up with the front edge. This will make putting on the molding much easier. (groove is the same as dado but because it is running with the grain it is a groove)

7. This what we are trying to avoid When students do not tape the sides together they often will make 2 of the same side as seen here. All of the time and material wasted can be avoided by taping the 2 pieces together

8. Cutting the groove/dado (groove is the same as dado but because it is running with the grain it is a groove)

9. Making the back Cut a piece of 1/8 mdf 9x9 for the backing. This piece is cut to fit. – length A= length of the top/bottom – length B= Distance between Dado/rabbet + ¾ Students will cut the back to fit their project. The measurement will vary depending on how they cut their first pieces.

10. Sanding and Assemble of case Sand all interior parts so after assembly they will not have to sand. It will be much easier when it is apart. Dry assemble box before gluing. After checking to see if it fits, then add glue to the rabbet and dado. Apply a small amount of glue to the grove to hold the back in place. Check for square by measuring corner to corner. If the box is not square it will be longer on one diagonal.

11. Top and Bottom Molding Cut a 24” piece of material to use as the molding for the base. Route the entire length of the board, then cut to 1 ¾ wide on the table saw. It is safest to route a wide piece then cut to 1 ¾”. By doing that, the students will keep their fingers away from the cutter as much as possible.

12. Top and Bottom Molding Cut a 45 o angle on one end of the molding piece and close to the end as possible. Place the end of the cut on the side of the project, mark the other side and cut a 45 the opposite direction.

13. Moldings continued After cutting the front piece to fit use the remaining piece for the sides. Cut a 45 on each end then mark to cut sides to length

14. Moldings continued Clamp and glue front molding even with the top edge of the bottom piece. The easy way for all the moldings to match up is to glue the front first, then add the sides when the front is set. Avoid using nails for the molding, it is hard to match the nail holes when filling and they will stand out. If time is an issue use a pin nailer so the nails will be at a min.

15. Moldings – top moldings The top molding will be done the same as the bottom, flip the clock over and put the molding on with it upside down. The top molding is only ¾ x ¾. For safety reasons it is important to instruct the students to route from wide piece, then cut the ¾ off the side. An injury is inevitable if students cut the ¾ piece and try to route it afterwards.

16. Crown Upper and Lower Have students measure the over all length and width of the top of their clock. Students cut a 22” piece of stock then cut it to the width of their individual clock. The measurement should be 5 ¾ x 11 ½ Crown lower length

17. Crown Upper and Lower After cutting the 2 rectangles, route the ends and one long side. Sand all parts then glue them together. After the crown upper and lower are glued together, glue the crowns to the main body of the clock.

18. Face Moldings To make the face moldings, cut a piece of material 18” long then plane it to ½” Route the length of the board on both edges and cut to ½” wide. Cut the 18” piece in half making 4 - 9” pieces Cut one end of all the pieces at a 45 o cut the other end at a 45o and fit the inside of the clock.

19. Finish and Assembly Sand all parts and fill any nail holes or imperfections. Finish clock with either stain or clear finish of choice. Drill a 3/8” hole in the center of the back piece.

20. Final Movement Assembly Assemble the clock parts in order Motor Face Large washer Large Nut Hour Hand Minute Hand Small Nut Second Hand