Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

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1 Hancock Wall Clock Assembly Instructions 77A50 07/28/94 Product #C7611X Introduction Before beginning the assembly of your Woodcraft precut clock kit, read these instructions and become familiar with the parts list, exploded views and the drawings which illustrate the text. Please read these instructions completely before you begin the construc- tion of your kit. Instructions or information in bold print are critical to ensure proper safety, set up, and avoid irreversible construction problems. These instructions are written so that anyone who carefully follows each step will successfully assemble this clock kit and create a beautiful Woodcraft clock. Important Notes About Solid Wood One of the unique characteristics of solid hardwood is the varying hues and patterns within a single piece of lumber. Since no two trees are identical, no two pieces of wood can be exactly alike. Each has its own characteristics created by nature, not by man. Unlike plastics and some veneers in which the grain pattern is symmetrical, solid hardwood has irregular and symmetrical graining, which adds to the overall beauty. In the same manner, the various shadings and colors within solid hardwood are part of its natural beauty. Many people prefer to have these various shadings show through the final finish. However, if you prefer a uniform color, stain the lighter color areas first to match and blend with the darker areas. Then, stain the entire clock to obtain the desired overall color. Although solid hardwood is unsurpassed for its beauty, it is by nature more susceptible to warpage than plywood or veneers. Therefore, special care is necessary while building your Woodcraft clock. Since solid wood can warp, shrink, or expand with changes in humidity, it is best to assemble and seal your clock as soon as possible. How- ever, if you cannot assemble your clock promptly, we suggest you store the parts in a dry area, keeping all parts flat. We cannot be responsible for changes in the lumber that occur during storage. Identifying the Parts As you unpack the shipping container(s) and identify each part with the Parts List. Both the Parts Layout and the Exploded view are helpful. As each part is identified, mark and place a label on the part. Possible confusion between similar parts can be easily resolved by careful comparison with the various drawings. NOTE: Throughout these Instructions, all references to left side or right side are to be interpreted with you facing the front of the clock. Work Area Before proceeding further, consider carefully your work space. A flat, firm surface about three by six feet is needed. Also, a safe and adequate space is needed to store parts until they are to be used. A muffin tray or egg carton is handy for organizing and storing the hardware and screws. Your work surface should be about three feet off the floor, such as a table covered with protective material. Finally, work in a well lighted, and particularly during finishing, well ventilated area. Tools The only tools essential to assemble your kit are a screwdriver, drill, ruler, and clamps. Throughout the assembly instructions each step lists additional tools that you will find make assembly easier and faster. A complete list includes: clamps square drill bits: glue pencil 1/32" gluebrush scissors 1/8" screwdriver ruler 11/64" awl drill 1/4" glue scraper hammer countersink pliers nail set Drilling Holes Most of the solid wood components of this kit have screw clearance holes pre-drilled and countersunk. When assembling, it is necessary to mark through these holes and to drill starter holes ( pilot ) holes in the other part. A ball point pen refill, an awl, or a sharp- ened nail make fine marking tools. Refer to the screw size reference charts that illustrates the best drill sizes. Drill starter holes from 1 /4" to 1 /2" deep. If you are using an electric drill, be very careful not to drill through the wood part. Starter holes must be drilled large enough for the screws you are using. If the holes are not large enough, you may crack the wood or strip the head off the screw. Other parts of the kit are not pre-drilled and may be tacked or stapled in place. For quality work we suggest that you attach these components with screws which we have provided, and the instructions are written accordingly. Sizes for drilling clearance holes through the parts are shown on the screw size reference page. When dimensions are given in the illustrations for hole location, follow these carefully. Clamps For some sub-assemblies, clamps are necessary to insure tight and accurate fit. Conventional pipe or bar clamps can be used if they are of sufficient length. Very useful, and often replacing the use of several conventional clamps, is a band clamp. Some assembly steps can be simplified with the use of C-clamps. When dry fitting an assembly make sure you have sufficient clamps for equal pressure over all the joints of that assembly at the same time before actually applying glue to the parts. Glue We recommend Titebond yellow aliphatic resin glue used according to the manufacturer s instructions. Fast drying or hot-melt type glues set too quickly, lack the bonding characteristics necessary, and can cause problems with fit. Remember, there are no short cuts if you want a good fit and a strong joint. NOTE: The splines or biscuits used in this case are manufac- tured from compressed wood. When you glue these splines, they will swell from the moisture in the glue. It is very important to assemble and clamp the case without hesitation once you have inserted the splines in place. Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

2 Use a gluebrush or cotton swab to spread the glue. A thin even spread on both parts is best. Clean up excess glue by scraping it off with a glue or paint scraper or use an old knife. Do not wipe the glue off with a damp cloth as the moisture of the cloth will thin the glue and allow it to soak deeply into the wood. This will show in the final finish of your case. It is important to thoroughly remove all excess glue. NOTE: Do not glue until the step by step instructions indicate you should do so. If you are unfamiliar with woodworking, we have included a small definitions appendix of terms used in these instructions. For more information on terms and procedures we suggest you refer to a basic woodworking book. 6 2 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

3 1 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

4 4 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

5 PARTS LIST Part No. Description Dimension T x W x L Quantity 1 Base 3/4" x 5 7 /8" x 11 1 /4" 1 2 Top 3/4" x 5 7 /8" x 11 1 /4" 1 3 Case Side L 3/4" x 4 3 /8" x 24 1 /4" 1 4 Case Side R 3/4" x 4 3 /8" x 24 1 /4" 1 5 Front Moulding 3/4" x 7 /8" x 9 3 /4" 1 6 Upper Door Left Stile 3/4" x 1 1 /4" x 9 3 /4" 1 7 Upper Door Right Stile 3/4" x 1 1 /4" x 9 3 /4" 1 8 Lower Door Left Stile 3/4" x 1 1 /4" x 13 1 /4" 1 9 Lower Door Right Stile 3/4" x 1 1 /4" x 13 1 /4" 1 10 Door Rails 3/4" x 1 1 /4" x 9 3 /4" 4 11 Chime Mount 3/4" x 3" x 8 15 /16" 1 12 Hanging Bracket 3/4" x 5" x 3" 1 13 Dial Mount 1/4" x 8 15 /16" x 10" plywood 1 14 Case Back 1/4" x 9 7 /32" x 24 1 /2" plywood 1 15 Cherry Knobs 3/8" Diameter 2 Note: Dimensions given are finished dimensions. Review all drawings prior to cutting. HARDWARE Case Assembly Screws #8 x 1 1 /4" FH Steel 2 Plywood Assembly Screws #4 x 5 /8" FH Brass 18 Magnetic Catch 5/16" Diameter 2 Magnetic Catch Screws #6 x 3 /8" FH Steel 2 Glass Keeper Strip (if glass is used) 1/4" 6' Keeper Strip Brads (if keeper strip is used) #20 x 3 /8" 25 Butt Hinges/Screws 1 1 / 2" Brass 4 Dial Mounting Screws #1 x 3 / 8" RH Brass 4 Assembly Screws #8 x 1" FH Brass 8 Optional Components Hood Door Glass 7 3 /4" x 7 3 /4" 1 Lower Door Glass 7 3 /4" x 11 3 / 8" 1 Note: Please measure the inside of the rabbeted door frames, for a more accurate fit of the glass components. Please obtain all hardware prior to construction and/or assembly so adjustments can be made if necessary. Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

6 1. Assembling The Case Parts: Case Left Side Tools: Clamps Case Right Side Square Case Bottom Awl Case Top Glue & Gluebrush Dial Mount Glue Scraper 8-#8x1 FH Steel Screws Drill & 1 /8" Bit 1. In a dry assembly, assemble Case Sides #3 and #4 in Case Bottom #1 as shown in the illustration. (Fig. 1) 2. Slip Dial Mount #13 into the grooves in the Case Sides. The lower edge of the dial Mount should be rounded off with a piece of sandpaper so that the Dial Mount sits flush in the bottom of the groove. 3. Attach Case Top #2 to the Case Sides. 4. Clamp the case together and check squareness. If the case is not square, be sure to correct it before proceeding. The Case Sides must be flush to the back edge of the Case Top and Bottom. 5. Mark the starter holes in the Case Sides through the Case Bottom and Case Top. 6. Disassemble case and drill starter holes in Case Sides which you previously marked. Be sure you have read the introductory section concerning Glue prior to proceeding. 7. Apply a small amount of glue in the grooves in Case Bottom #1 and Case Top #2 which will receive the Case Sides. Apply glue in the grooves in the Case Sides which will receive the Dial Mount. Spread the glue evenly. DO NOT GLUE in the Chime Shelf. 8. Assemble the case, clamp, and check for squareness. Make sure the Dial Mount is sitting in the bottom of the grooves in the Case Sides, and that the Case Sides are flush with the rear edge of the Case Bottom and Case Top. After you have checked everything, screw the Case Top and Case Bottom to the Case Sides with #8 x 1" FH screws. 9. Clean up any excess glue. Set assembly aside to let the glue dry. 2. Door Assembly Parts: Upper Door Left Stile Tools: Clamps Upper Door Right Stile Square Upper Door Rails Glue & Gluebrush Lower Door Left Stile Glue Scraper Lower Door Right Stile Lower Door Rails 1. In a dry run assemble Lower Door Left Stile #8, Lower Door Right Stile #9, and two Door Rails #10 together. Clamp and check assembly for square. 2. When satisfied with the fit of all parts, disassemble door and prepare to glue. 3. Apply a thin but even coat of glue to all mating surfaces and clamp parts together. 4. Check door for square. It is extremely important that the door be square or it will not fit the case. 5. Clean up any excess glue and set assembly aside to dry. 6. Repeat sequences 1 through 5 using the Upper Door Left Stile #6, Dial Door Right Stile #7, and two Door Rails #10. 6 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

7 3. Attach Case Moulding 1. Place assembled Case on its back. Position the Upper and Lower Doors in the Case, placing the Case Molding #5 between the doors. 2. The spaces at the top and bottom of each door must be equal for the doors to open smoothly. One way to assure this is to slip several pieces of kraft paper into the spaces so that they are all equal. 3. When the Doors and Case Molding are evenly positioned, mark from the back through the Case Sides the location of the screw holes to attach the Case Molding to the Case. 4. Drill starter holes in the Case Molding and attach to the Case with 2 - #8 x 1 1 /4" FH screws. 5. Mark the position of the hinge recesses onto the edge of the Doors. 4. Attach Hanging Bracket Parts: Assembled Case Tools: Screwdriver Hanging Bracket Glue & Gluebrush 2- #4 x 5 / 8 FH Screws 1. In a dry run insert the Hanging Bracket #13 in position as shown. (Fig.4) 2. Mark starter holes through the Bracket onto the Case Top. 3. Remove Bracket and drill starter holes as marked. 4. Apply a thin even coat of glue to the mating surfaces and attach the Hanging Bracket to the Case with 2 - #4 x 5 /8" FH Screws. 5. Hang Doors Parts: Assembled Doors Tools: Screwdriver Assembled Case Awl 4-Butt Hinges Ruler 2-5 /16 Magnetic Catches Pencil 2 - #6 x 3 /8 FH Steel Screws 1. Place a hinge on the inside of the Right Stile positioning it flush to the outer edge and in line with the marks made previously on the edge of the Door in Step Mark the position of the screw holes through the hinge. Drill starter holes in the door and attach hinge to the door using screws provided with hinges. 3. Repeat above 2 sequences for the other hinges. Make sure that once the hinges are attached to the door they will line up with the recesses cut in the Case Side and that the door will have an even space at the top and bottom. 4. Position the hinges in the recesses cut in the Case Sides and mark the location of the hinge screws. Drill starter holes in the Case Sides and attach the hinge to the Case. 5. After the doors are installed check to see that they close properly. If the doors are off at all, they should be corrected before proceeding. 6. Insert the magnetic catches in the holes drilled in the Left Case Side. 7. Mark on the outside edge of the door the location of the magnetic catch. As shown in the insert (Fig. 4), measure in from the mark 3 /8". Drill a starter hole and screw in #6 x 3 /8" FH steel screw so that the head is flush with the wood. Repeat for the other door. 8 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

8 6. Install Case Back Parts: Case Tools: Screwdriver Case Back Drill & 5 /64 Bit #4 x 5 /8 FH Brass Screws Awl 1. Insert #14 Case Back into rear of Case and check for fit. It should not fit too tightly. With an awl, mark starter hole locations. (Fig. 6) 2. Remove the Case Back from the Case and drill 5 /64" starter holes as marked. 3. Install Case Back in Case using #4 x 5 /8" FH Brass Screws. DO NOT GLUE. 7. Finishing 1. Before proceeding with the installation of the glass, dial, and movement it is best to stop at this time and finish the case. Remove the doors and all hardware from the case. 2. Sand all the wood parts with progressively finer grades of sandpaper. We recommend starting with 120 grit and finishing with 220. Always sand with the grain of the wood. When you have finished sanding all the parts, clean them of all dust by vacuuming or using a tack cloth. 3. The wood can be painted, stained, or left natural as you choose. It should be sealed with a topcoat such as varnish, lacquer, polyurethane, or the wood can be oiled. Finish all the wood parts. Do not apply finish to the holes in the Doors or to the tenon on the Door Pulls. 4. If this is one of your first finishing projects and you are unsure how to proceed to get the effect you want, we suggest you obtain a copy of a good general book on wood finishing. 5. Do not rush the finishing of your clock. Take your time, be very careful, experiment on scrap wood, and you will be rewarded with a truly handsome clock. 8. Glass Assembly Parts: Doors Tools: Drill Glass for Upper & Lower Tack Hammer Doors (not supplied) Nail Set Glass Keeper Strip Pliers Brass Brads Ruler 1. Place the Door face down on your work surface being very careful to protect its finish. 2. Set glass or panel in opening. 3. Lay out the Glass Keeper Strip on your work surface. Drill a very small hole through the keeper as shown in Fig. 6. Measure about 3"- 4" and repeat. Do this for the entire length of the keeper strip. 4. Place the keeper around the outside edges of the glass or panel. Put a brad into the hole you drilled and drive the brad into the wood with a tack hammer and nail set. BE CAREFUL NOT TO SCRATCH OR BREAK THE GLASS. A pair of pliers may be helpful for starting the brads into the keeper strip. 5. Repeat process for the other door. 8 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

9 9. Dial Installation Parts: Case Tools: Screwdriver Dial Awl 4 - #1 x 3 /8" RH Brass Screws 1. Center the dial on the dial mount. 2. Mark the location of the screw holes onto the dial mount. Make a starter hole with an awl, and attach the dial to the dial mount with 4-#1 x 3 /8" RH Brass Screws. (Fig. 8) 10. Movement Installation Parts: Case Tools: Screwdriver Movement & Chime Awl 1. Lay the case face down on your work surface. 2. Center the movement on the inside of the dial mount. If necessary, adjust the movement mounting brackets to align with the dial mount. (Fig. 9) 3. Measure from the top edge of the movement at each corner to the inside of the case top. The top edge of the movement must be parallel to the case top. 4. Mark through the mounting brackets onto the dial mount. Drill starter holes and attach movement to dial mount with 4 wood screws supplied with the movement. Place two washers between the bracket and the screw head on each screw. 3341X Movement Only 1. The chime block for the 3341X Bim Bam movement has three rods. It is attached to the chime shelf as illustrated with 2 machine screws and 2 washers. (Fig. 10) 2. Slip the chime shelf into the case as shown. The rods should be aligned with the hammers on the movement so that the hammers will strike the rods squarely. The hammers should be about 1 /16" - 1 /8" away from the rods when at rest. The hammer stems can be bent for correct alignment. Mark the location of the chime shelf in the case. 3. Place a small amount of glue in the groove in the case sides where the chime shelf will sit. Slide the shelf in place and set case aside for glue to dry. NOTE: The design of this case will not accommodate the calendar feature of the 3341X movement. 3366X Movement Only 1. The chime block for the 3366X Westminster Chime movement has five rods. It is attached to the chime shelf as illustrated with 2 machine screws and 2 washers. (Fig. 11) 2. Slip the chime shelf into the case as shown. The rods should be aligned with the hammers on the movement so that the hammers will strike the rods squarely. The hammers should be about 1 /16" - 1 /8" away from the rods when at rest. The hammer stems can be bent for correct alignment. Mark the location of the chime shelf in the case. 3. Place a small amount of glue in the groove in the case sides where the chime shelf will sit. Slide the shelf in place and set case aside for glue to dry. Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

10 3370X Movement Only 1. The chime block for the 3370X movement has a single coil gong. It is attached to the chime mount as shown. (Fig. 12) 2. Slip the chime mount into the case. The hammer of the movement should be aligned so as to strike the straight portion of the gong. The hammer stem may be bent if necessary. 3. Place a small amount of glue in the grooves in the Case Sides where the chime mount will sit. Slide the mount into place. Note: The design of this case will not accommodate the calendar feature of the 3341X movement. Quartz Movement Only 1. To install a quartz movement simply insert the hand shaft of the movement through the dial hole and secure with included hardware, as shown. (Fig. 13) 2. Clip the pendulum to desired length and attach 11. Door Knob Assembly 1. Measure the tenon of each door knob. If it is over 9 /16", the tenon should be reduced in length by sanding or cutting it to 9/16". (Fig. 14) 2. Apply a very small amount of glue to the tenon and install in the door stile. 3. Be sure to clean up any excess glue being very careful not to scratch the finish. 10 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV

BUILDING A STORM DOOR

BUILDING A STORM DOOR BY NEAL BARRETT Illustrations by George Retseck If you're in the market for a storm door, you probably know that there are many styles and models available. However, most of them