Making Wide Panels

Let's face it, lumber just isn't available in the widths that we need for most projects. So what do you do the next time you're building a solid wood tabletop or cabinet door? Simple, make a wide board yourself. It's easier than it sounds.

For generations woodworkers have been building larger panels by gluing together a number of smaller boards. The process is relatively simple but there are a few tips to help ensure good results and a flat panel.

Wood Movement - The first thing to keep in mind is that wood moves. Seasonal moisture changes in your home will cause the wood to shrink and swell. These changes generally occur across the board's width. Larger panels may tend to amplify this problem. Because of this, it might be better in some cases to use plywood instead of solid wood.

What are the basic steps to making wide panels?
The basic process for making a larger panel is to take a number of boards and prepare the edges so they are perfectly perpendicular to the face of the board. The edges of the individual boards are then coated with glue and clamped together. The process is as simple as it sounds but there are a few things to keep in mind.

What tools can I use to prepare the edges of the individual boards?
One of the most common methods for preparing boards to be joined together is to rip them on a table saw and then use a jointer to smooth the edges. A jointer is a power tool that planes the surface smooth. You don't have to own a jointer to make a good panel. Some saw blades leave a smooth enough cut to glue up straight from the saw. You can also use hand planes and other tools to smooth the edges. Another trick is to use a router fitted with a straight piloted bit to smooth out the edge.

Are there any special tricks when laying out the boards?
It's best to arrange the board so that the colors are as close to each other as possible. Ideally, when glued, the panel should look like one solid piece of wood. The second thing to remember when laying out the board is to try and arrange them in alternating end grain patterns.

What type of wood should I use?
Most of the commonly available hard and softwoods are suitable for building larger panels. However, care should be taken to ensure all of the wood you are using is kiln dried. Kiln dried wood has been dried in a special furnace and is more dimensionally stable and less likely to warp and crack with time.

What type of glue should I use?
Generally yellow glue is the best. Titebond II works well and can be used for outside furniture. The ultimate glue for external use is polyurethane glue such as ProBond. Polyurethane glues tend to be a little harder to work with and cost more. One of the most important things to remember is that if the glue is too thick it won't squeeze out of the joint and allow the joining pieces to touch. Also remember to use new glue. If the bottle is too old to remember when you bought it, get a new one. Glue does have an expiration date and will fail to hold-up under use. With yellow glue, if the bottle has been exposed to freezing temperatures it's time to throw it away. "Stringy" yellow glue is a sign that it has gone bad.

How much glue should I use?
Be sure to use only enough to cover both sides of the mating pieces. Too much glue can prevent the boards from making solid contact with each other. Too little or too much glue can result in a weak bond. When you clamp the boards together, enough glue should squeeze out that there is a constant layer of glue drop beads. Long drips may indicate that too much glue has been used and gaps in the "squeeze out" can be an indication of insufficient glue in the joint.

What should I do about the glue that squeezes out of the joints?
Glue squeezing out of the joint is a good thing. It shows that the joint has enough glue and is thoroughly covered. Unfortunately this means you have more to clean up. The best thing to do is wait until the glue begins to set up or gel and then scrape it off with a putty knife or chisel.

How big should the panel be?
You should oversize the panel by an inch or two to allow for trimming and final sizing.

What types of clamps do I need?
Generally you can use pipe clamps or bar clamps. There are also a number of more exotic versions on the market that are designed to clamp from both directions and ensure the boards align correctly.

How much pressure should I use when clamping?
One of the biggest mistakes woodworkers make is over-clamping. You only need to apply enough pressure to push the boards together firmly. If you use too much pressure the clamps will tend to bow and leave the panel with a cupped shape. One trick to counteract this effect is to alternate the side of the board that the clamps are placed. This alternation of the clamps tends to even out the tendency to cup the wood because the clamps are pulling against each other.

Should I dry fit the boards first?
It's always a good idea to dry fit the boards together before you add glue. This will allow you to arrange them so the color and grain patterns match each other. It will also help to identify any edges that are not straight and smooth.

Can I use warped lumber?
It is generally not a good idea to use warped boards in your panel. They can often be forced into position during clamping but they will still have internal stresses in the board and try to return to the warped position.

Do I need to use dowels or biscuits to reinforce the joint?
While using dowels or biscuits to reinforce the joints is not required it does help strengthen the joint and aid in alignment during the gluing phase. Another option is to use a router to cut a "glue joint" along the edge of the board. The glue joint works by adding more surface area to the joint, allowing the wood in the joint to contact over a larger surface. Pictured to the right is a Whiteside bit available from www.routerbits.com 

What if I have a Question?
If you have a question about anything you read in this article please feel free to contact us at woodmaster@woodzone.com