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I don't do a lot of trim work, but when I do, it's often
stain-grade or pre-painted, and the miters have to be perfect!
I hang doors, mostly, so I rarely have a full-size work table
set up, just a door bench. Most of the casing I work with
is small. At first, I thought it was too small to survive
a Clam Clamp, but I've learned better (more on that later!).
So I came up with a method for pre-assembling casing that
didn't require a large table but guaranteed tight miters.
There's no staples, no biscuits, just glue. But the pre-assembled
frames are so strong you can carry them in one hand.
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which are perfectly square and have a thin strip bordering
two edges. I start by clamping the legs to two of the
jigs with A-clamps. A single sawhorse is all I need for
this technique. The back of each jig is covered with a
non-slip material so the jigs won't slide off my saw horse
(available at home centers: Solid Grip Liner, Contact
brand $4.95 for a 18" x 48" roll). |
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Next I glue up the miters
with Titebond.
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Then I place a large spring clamp on each
corner. These clamps are similar to the old Ulmia clamps.
They apply a lot more pressure than Collins Spring Clamps,
but the pressure is all right on the miter. They leave
a single hole in the back of the casing, which is easy
to fill. |
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On wood moldings I nail the corners with
a brad, but on mdf moldings, I let the glue do all the
work--mdf casing splits unless you nail it with a 23ga
pin. |
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The assembly jigs do all the work. They
keep the pieces square, and the A-Clamps help hold the
casing flat, so the miters come out perfectly . I made
several sets of these assembly tables. |
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With several assembly jigs, I can leave
a frame to dry while assembling another one. As soon as
I finish a frame, I pick it up off the sawhorse, carrying
it by the assembly jigs. It only takes a few clamps to
stay busy. |
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The glue sets in about ten minutes. By
that time, you can carry the frame in one hand and even
shake it and the miters won't open!
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I sent the pictures you just looked at to
Gary about two months ago (that's how long it's taken
him to put them on his website!). In that time, I've figured
out a much better way to preassemble casing, especially
small casing. Now I use a Clam
Clamp |
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To use Clam Clamps
( see
Gary's tool review) on thin casing, I rabbet
the assembly tables. For typical 9/16 casing
or 5/8 thick casing, I make the rabbet 5/32
in. deep--that centers the clamp pins perfectly
on the casing. Because the casing is so small,
I remove the two lower pins, otherwise the Clam
Clamp puts too much pressure below the miter.
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This technique works much better wtih
Clamp Clamps, but the process is the same: Always
clamp the casing to the assembly tables first. I
position the casing so that it hangs over the rabbet
just a bit.
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Once the Clam Clamps are on, the assembly
tables make it much easier to move the frame. You
can't get this kind of clamping pressure from spring
clamps, and when you use Clam Clamps, the joints
are so durable, firing a brad nail through the miter
becomes a waste of effort. |
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