Make the ENDS
To make the ends, I cut a length of 2×6 for the three pieces that make up the end assembly. These are ripped on the table saw to width then back to the mitre saw to cut down for each component.
One of these blocks I take to the drill press for the dowel hole.
I’ll then drill the pilot holes for assembly with an eighth bit.
The dowels need to be sanded down to reduce their diameter to fit inside the pipes. I use a disc sander for this. You could also use a small hobby sander or a belt sander instead.
These are then cut to length and glued and tapped into the holes.
I assemble the ends with glue and screws checking that everything lines up well and is square.
A clamp helps to hold the pieces while I run in the screws.
Test Fit and Assembly
With all the parts of the form ready, I assemble it and test the fit.
I number each form and all the parts so I can reassemble it again the same way.
I used particle board screws for this but there’s some self drilling cabinet screws, for a few more dollars, that would save time and pre-drilling.
I filled any knot holes or screw heads with a bit of wood filler. Some of the insets had holes predrilled from the other plywood forms. They were the right size so I attached them with screws from the top.
No worries. Wood filler filled the screw heads and only took a minute to apply.
I remove the screws and disassemble the form and apply two coats of Food Grade Mineral Oil.
This oil is sold as Butcher’s Block or Cutting Board oil. You can also buy it in Feed Stores for about half the price.
I liberally apply it with a cloth. It doesn’t take long and each coat took about 10 minutes per form.