Step 1: Gather Materials and Tools
5/8" or 3/4" Straight Cutting Bit
1/4" Slot Cutting or Rabbeting Bit
1 X 4 Super Strips
MDF or Plywood for Jigs
C Clamps or other hand clamps
1/4" Dowel rod
Pipe Clamp (optional)
Step 2: Create Jigs
The arched jig is pretty simple, just sketch out the curve on the MDF/Plywood. If you have the ability to glue strips together, you can make a steeper curve. That being the case, I can't give you plans for that curve.
The jigs for the legs are simple. If you don't have a bushing setup, you can change the jig a bit to add a border to create a 6" channel for the router base.
When using the jig, clamp down both sides of the bamboo. The clamps are primarily to keep the bamboo straight. The jig should be tight to so the bamboo cannot roll side to side. Cut through just the top layer of the bamboo, the ends of each segment will remain for structural purposes.
Step 3: Route Tenons, Route Grooves and Cut Side Strips
The side strips are as thick as the groove in the bamboo is wide. They will be just wide enough to reach the surface of the bamboo.
Again, the cuts will be made when the ends of each segment where the strips cross them.
Step 4: Cut Fencing and Sand/Stain Bamboo
Stain everything before you glue. Any exposed wood without stain may have glue on it. After it is together, you may not have the option to correct finish mistakes. And with all wood projects, though no one else will notice...IT WILL HAUNT YOU FOREVER!
Step 5: Glue, Clamp, Pray, and Nail
Wear latex or vinyl gloves...don't get this stuff on your hands. It is really bad for you. There is an MSDS sheet for similar glues that takes days to read...
If you screw up and can't get the panel in place, don't worry. You can put it in afterwards, it is just a bit more difficult.
Clamp it, check for square (or approximate square) and tack everything together. The dowels will be added later.
More to follow as I complete the project.
The carvings were all done by my CNC, and was the inlay (if you can see it).