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Broken Arch Mantel Clock Plans

This stately Mantel Clock is reminiscent of the Broken Arch clocks made in Connecticut after the Revolutionary War. The simple lines of this flat capped broken arch style are less ornate than the scroll or swans neck designs but its beauty has withstood the test of time. This is really an easy project to make. Designed for the woodworker with basic woodworking skills, it requires a table saw, scroll saw, router, drill press, and dowel jig. The broken arch pediment and the base trim are the only parts that require scroll cuts. The clock pictured is made of solid cherry with a medium walnut stain. The chiming quartz pendulum movement, brass finial, and brass dial, and other hardware is readily available. Sources for the necessary hardware are listed on the Materials List page. The finished clock is about 21" high, 12" wide and 6" deep. the dial is 7 1/2" square.

Copyright 2005 by Robert E. Reedy All rights reserved

Broken Arch Mantel Clock Plans

Table of Contents

Materials List .................................................................................................... 1 Base Drawings .................................................................................................. 2 Base Trim Drawings ......................................................................................... 3 Case Sides Drawings.......................................................................................... 4 Case Sides Hinge Location ............................................................................... 5 Broken Arch Pediment ...................................................................................... 6 Crown Caps Drawings ....................................................................................... 7 Dial Frame Drawings ........................................................................................ 8 Door Parts Drawings ......................................................................................... 9 Back Cover Drawings ..................................................................................... 10 Base Assembly ................................................................................................ 11 Top Assembly ................................................................................................. 12 Case Assembly ................................................................................................ 13 Dial Frame Assembly ..................................................................................... 14 Door Assembly ............................................................................................... 15 Magnetic Catch Installation ............................................................................ 16 Door Glass Installation ................................................................................... 17 Door Installation ............................................................................................. 18 Dial Assembly Installation .............................................................................. 19 Back Cover Installation .................................................................................. 20 Broken Arch Pediment Full Size Pattern ........................................................ 21 Speaker Holes Pattern ..................................................................................... 22

Copyright 2007 by Robert E. Reedy, Vandalia, Ohio All Rights Reserved

Dial Frame Segment

Page 1
Qty Item 1 1 2 1 2 1 2 2 4 2 2 1 2 2 2 2 2 1 1 1 1 Length Width 4 4 4 3 1 1 1 1 1 1 1 1 5/16 8 7/16 8 7/16 10 9 Thick Material 1/8 3/8 3/8 3/8 3/8 1/8 1/8 1/8 Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Hardwood Single Strength Glass Single Strength Glass Hardboard Hardboard
Door Side Base

Dial Frame Segment Dial Frame Segment Base End Trim

Materials List

Note: The door glass pieces should be 1/16 smaller than the openings in the door on each side. I recommend you measure the openings after the door is completed and then cut the glass accordingly. This allows for slight expansion and contraction of the wood.

Qty Item 1 1

Size

Source

72"

Side

Brass Dial 7 By 7 Klockit (Stock No. 26878) Clock Movement Klockit (Stock No. 12232) Bob Diameter: 2 , Pendulum Length: 8
(Pendulum length is from center of dial to tip of pendulum)

Sources
KLOCKIT www.klockit.com MURRAY CLOCK CRAFT www.murrayclock.com
Broken Arch Pediment

The drawings to the right should help you determine how to efficiently cut the parts from 5 1/2" wide by 72" hardwood boards. The smaller parts are not pictured because they can be cut from smaller pieces you may have in your scrap bin.
Copyright (c) 2007 by Robert E. Reedy
All Rights Reserved

Cap

Cap

Door Divider

1 1 1 1 1

Set of Hands (Black Serpentine)3 1/8 Brass Finial 3H x 1 3/8 Dia. Brass Door Knob 7/16 By 3/8 Magnetic Catch 3/8 Door Decal 1 By 4

Klockit (Stock No. 67931) Klockit (Stock No. 38128) Klockit (Stock No. 39049) Klockit (Stock No. 39011) Murray Clock Craft (Decal #5)

Top

Door Bottom

Base ............................................ 11 Top .............................................. 11 Sides ........................................... 14 Broken Arch Pediment ................ 11 Crown Caps ................................ 6 Finial Seat ................................... 1 Front & Rear Base Trim .............. 12 3/4 End Base Trim ............................ 5 3/4 Dial Frame Sides......................... 9 Door Side .................................... 14 Door Top & Bottom ..................... 9 Door Divider ................................ 8 Top & Bottom Glass Retainer ..... 7 Middle Glass Retainer................. 7 Upper Side Glass Retainer ......... 8 Lower Side Glass Retainer ......... 4 Back Mounting Strip .................... 9 Upper Door Glass ....................... 8 Lower Door Glass ....................... 4 13/16 Back Cover.................................. 14 Dial Mounting Board.................... 10

Dial Frame Segment

Base End Trim

Rear Base Trim

Side

Front Base Trim

Door Side Door Top

Base Drawings
Page 2
11 1/4"

1/2"

3/8"

Base
(Top View)

1/2"
3/8"

3/8"

Drill four 3/16" diameter holes 3/8" from each end and 1/2" from the front and rear edges as shown. These holes are for the flathead screws that attach the sides to the bottom. These holes go completely through the wood and should be countersunk on the bottom for #8 screws.
1/2"

4 1/4"

3/16" Dia.

3/8"

1"

Base
(Top View)
1/4" Dia.

1"

3/8"

1/2"
3/8"

3/8"

Drill four 1/4" diameter dowel holes in the top. They are 3/8" from each end and 1" from the front and rear edges as shown. These holes are for the 1/4" by 1" dowel pins that align the sides to the bottom. These holes should be only 1/2" deep.
1"

3/8"

Front

1"

Next, drill three 1/4" diameter dowel holes in the front and rear edges. Then drill two 1/4" diameter dowel holes in each end as in the edge and end views shown below and to the right. These holes are for the 1/4" by 1" dowel pins that align the trim to the bottom. These holes should be 3/4" deep.

1/2"

3/8"

(End View)
1/2"

1 1/2" 5 5/8"

3/8"

(Edge View)
1 1/2"

Note: You will notice that the dowel holes for the end trim and the 3/16" screw holes through the top will intersect. This results in the dowel pins blocking the screw holes. Not a problem because the holes can be easily redrilled after the trim is attached.
Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Base Trim Drawings

Page 3
12 3/4" 3/4" 45

(Top View)

Front and Rear Trim

11 1/4"

(Two required)

45

5 3/4"

Here are top views of the bottom trim pieces. The trim pieces will be attached to the bottom with 1/4" dowel pins. You must drill the 1/4" dowel holes to the exact dimensions as shown below for a good fit.

3/4"

45

End Trim

(Two required)

45

(Top View)
4 1/4"

Drill the dowel holes in the trim pieces as shown in the drawings below. These holes should be 1/2" deep.
3/8"

Front & Rear Trim

5 5/8"

(Edge View)
5 5/8"

1 1/4"

1 1/2"

3/8"

1 1/2"

3/8"

1 1/4" 1/2"

End Trim
(Edge View)
5 3/4" 1/2"

Cut a section from the front trim and both end trim pieces as shown in the drawings to the right and below. The dotted lines represent where to cut. removing this material makes it look like the clock is sitting on legs. It is not necessary to remove material from the rear trim.

3/8"

End Trim
R1/2" 1 1/2"

(Edge View)

1/2" 1 1/2"

End Trim
R1/2" 1 1/2" 1/2"

(Edge View)

1 1/2"

Bottom
(Top View)

Here is a top view showing the four trim pieces attached to the bottom with the 1/4" dowel pins. As mentioned before, the four screw holes that will be blocked with the dowel pins will need to be re-drilled after the trim is glued in place.

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Case Sides Drawings

Page 4
4 1/4"

Top View of Side Pieces

1 1/4" 1" 3/8" 1/2" 1/2" 1"

Bottom View of Side Pieces

1" 3/8" 1/2" 1/2" 1"

Drill two 1/8" pilot holes in the top and bottom of each side as shown in the drawings above. These pilot holes should be 1/2" from each edge and about 3/4" deep. These holes are for the #8 woodscrews used to secure the sides to the base. Next, drill two 1/4" dowel pin holes in the top and bottom of each side. These dowel pin holes should be 1" from each edge and 1/2" deep. Dowel pins are used to keep the sides properly aligned with the base.

(Two Required)

Side

14 3/4"

Cut the back rabbets, dial mount slots, and decorative bead.
Use your router to make a 1/4" bead along the front edge of each side as shown.

1/4" 3/16"

Right Side
1 1/4"

Cut the rabbets in each side for the rear cover. They are 1/2" wide and 3/16" deep.

Cut a slot in each side to hold the clock dial backing plate in position. These slots are 1/4" wide and 1/4 inch deep.
1 1/4"

3/16"

Left Side
1/4"

2 1/4"
Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Side Hinges Location

Page 5
4 1/4"

1"

1/4"

Drill pilot holes for the brass door hinges using a 1/16" bit. Drill these holes about 3/8" deep. Note: The exact location of the hinge pilot holes depends on the hinges you will be using. You will need solid brass or brass plated hinges that are from 1" to 1 1/4" high and from 1" to 1 1/4" wide. These hinges can be found at most hardware stores or hobby shops. The ones I used on this clock are 1" high and 1" wide when fully opened. They also create a 1/8" gap between the door and right side of the clock when the hinge is installed and the door is mounted. I suggest you obtain the hinges before drilling the pilot holes and mark the location of the holes using the hinges you will be using. This will ensure the holes are drilled accurately.

14 3/4"

Right Side

1/4"

1"

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Broken Arch Pediment

Page 6

5 5/8"

4 1/2"

1" R5/8" 3 1/4"

Crown Pediment
Front View

1 3/4" 1"

11 1/4"

Cut the Crown from 3/4" thick hardwood according to the dimensions shown above. A full size pattern is also included for your convenience..

3"

1"

Rear View
3/8" 1 1/2" 4 1/8" 11 1/4" 1 1/2"

Drill 1/4" dowel holes as shown above, these holes should be 5/8" deep. The dowel holes on the top surfaces are for mounting the Caps and should be centered front to back (3/8" from the front surface). The three holes along the bottom are for mounting the Crown to the Top piece.

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Crown Caps
Page 7

6"

Cap (2 required)
(3/4" Thick)

1 3/4"

Make two Caps from 3/4" hardwood as shown above.

1 3/4"
R3/8"

6"

7/8"

5 1/8"

End View

Side View

Create the bead along the edges with your router using a 3/8" radius beading bit. The bottom surface should be 7/8" wide by 5 1/8" long. This provides for the bottom surface of the Caps to extend 1/16" over the edges of the Crown.

1 1/16"

3"

1 1/16"

Top View of Finished Cap

Drill 1/4" dowel holes as shown above, these holes should be 1/2" deep.

1 1/4"

1"

Finial Seat
(1/8" Thick)

Make the Finial Seat from 1/8" thick hardwood as shown above. Drill a hole through the center the same diameter as the outer diameter of the Finial mounting screw.

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Dial Frame Drawings

Page 8
9 3/4" 45

Dial Frame Side

(4 Required)

45

1 1/4" 1/2"

End View

Cut a relief 1/4" wide by about 1/32" high to provide room for the thickness of the dial.
3/8" 5" 1/4"

Dial Frame Support

(2 Required)
10 1/4" 5/8" 5/8"

1 3/4"

Dial Mounting Board

Made of 1/4" thick hardboard.

1 3/4"

4 7/8"

5/16" diameter hole is centered top to bottom and side to side.

5/8" 5/8" 9 3/4"

Drill and countersink five holes as shown. These holes are for mounting the Dial Mounting Board to the Dial Frame.
1 3/4" 1 3/4"

5/8"

5/8"

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Door Parts Drawings

Page 9
9 1/2" 45

Door Frame Top & Bottom

(2 Required)

3/4"

1"
End View

3/4" 1/2"

1" 1/2" 3/4" 1/2"

End View

5/16" 3/8"

7 1/2"

Door Frame Divider

(1 Required) Top View

Door Frame Side

14 1/2"

Bottom View (2 Required)

7 1/2"

Side View
8 1/2"

5/16"

Glass Retainers
7 1/2"

3/8"

Middle Glass Retainer (2 Required) End View

1/2" 8 1/4"

5/16"

3/8"

Upper Side Glass Retainer (2 Required) End View

1/2" 7 1/2"

1/2"

45

3/8"

Top & Bottom Glass Retainer (2 Required) End View

1/2"

3/4" 3/8"

1/2"

4 3/4"

Lower Side Glass Retainer (2 Required) End View

Copyright (c) 2007 by Robert E. Reedy
All Rights Reserved

1/2"

Back Cover
Page 10

9 3/4"

1/2" 1/2" 1/2"

Back Mounting Strip (2 Required)

End View
10 3/4" 5 3/8" 1/4"

4"

If you will be mounting a speaker on the Back Cover, use the Speaker Holes Pattern to layout and center punch the holes. Be sure you have clearance from the edges of the cover and the wires won't interfere with moving parts. Don't place the speaker in the lower half of the clock as it would be visible through the lower door glass.

5"

2"

2"

4"

Cut out a hole as shown for access to the movement.

14 3/4"

Movement Access Cutout

Drill and countersink ten holes for #6 flat head screw along the edges as shown. Thgey should be 1/4" from the edge of the Back. These holes are for mounting the Back to the Case.

Back Cover

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

5"

Base Assembly
Page 11

Attach the Bottom Trim to the Bottom with 1/4" dowel pins and glue. After the glue has completely dried, sand all surfaces so the corners look good and the top surface is smooth.

Next, use a 5/16" radius beading bit to create a bead around all four edges as shown.

3/4 "

Attach a Back Mounting Strip to the Bottom with glue and 1" brads as shown. The strip should be 3/4" from each end of the Bottom and 3/16" from the rear of the Bottom.
3/4 "

3/16 "

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Top Assembly
Page 12

Apply glue to the mating surfaces and dowel pins and assemble the Caps to the Crown Face as shown. An easy way to clamp the Caps to the Crown Face is with rubber bands. Use as many rubber bands as necessary to securely hold the Caps in place until the glue dries. Next apply glue to the mating surfaces and attach the Finial Seat as shown above. Temporarily secure the Finial Seat with a flathead screw until the glue dries. Be sure the Finial Seat is positioned squarely.

3/4 "

Attach a Back Mounting Strip to the underside of the Top with glue and 1" brads as shown. The strip should be 3/4" from each end and 3/16" from the rear of the Top.
3/4 "

3/16 "

Apply glue to dowel pins and mating surfaces of the Top and Crown. Clamp securely until the glue is dry.

Attach the Finial

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Case Assembly
Page 13

Note: Do not glue the Sides to the Bottom. You will need to remove the Bottom when installing the Dial Assembly, Apply glue to dowel pins and mating surfaces of the Top and Sides. Press the Top firmly over the dowel pins.

Secure the Sides to the Bottom with four 1 1/2" # 8 flathead screws. Insert the screws through the bottom. (Screw holes should already be drilled). After the Bottom is secured with the screws, clamp the Top to the Sides until the glue sets up. Be sure the Case assembly is square while the glue is setting up. It must be square for the door to fit properly! Remember: Do not glue the Sides to the Bottom!

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Dial Frame Assembly

Page 14

Glue the metal dial to the Dial Mounting Board using contact cement. The dial should be centered on the mounting board side to side and top to bottom.

Apply glue to the mating surfaces and assemble the Dial Frame. Clamp with corner clamps.

12 1 11 10 9 8 7 6

2 3 4 5

12 1 11 10 9 8 7 6

2 3 4 5

Position the Dial Frame over the dial and mounting board so it is centered side to side and flush top to bottom.

Secure it with six 1/2" #6 flathead screws from the back side of the mounting board.

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Door Assembly
Page 15

7 1/2"

7"

Front View

Assemble the Door as shown. Use wood glue and corner clamps to clamp the corners. Glue and clamp the Divider in place so upper opening is square. Put the Brass Knob 7" from the top and 1/2" from the edge of the door. This location is slightly higher than center. If you place it exactly centered top to bottom, it may actually look too low because of optical illusion.

Rear View

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Magnetic Catch Installation

Page 16

Back Side of Door

Dial Frame

4 3/4"

4 7/8"

For the Door, you only need a 1/4" # 6 flathead screw to contact the magnetic latch. If a washer comes with your latch, you can discard it. Drill a 1/16" pilot hole hole in the DoorFrame for the screw as shown to the right. Do not drill the hole completely through!

11 12 1 10 9 2 3 4 7 6 5

1/4"

3/8"

Drill a hole in the Dial Frame for the magnetic catch as shown above. ( I recommend using a brad point drill bit because it will cut a cleaner hole than a common twist drill.) The back side of the Dial Frame will be covered by the mounting board. I won't matter if you drill the hole completely through. The hole should be the correct size for the catch you're using. You may want to experiment on scrap wood to determine the exact size. Install the catch by inserting it until it is flush with the surface of the wood.

Note: An easy way to ensure the screw head lines up correctly with the magnet in the catch is to wait until the clock case is assembled and the door is mounted. then, you can place the screw head on the magnet and close the door so the point of the screw makes a mark on the inside of the door. This will be the exact location for the screw.

Copyright (c) 2007 by Robert E. Reedy

All Rights Reserved

Door Glass Installation

Page 17

Install the glass panels as shown above.

Install the glass retainers as shown to the right. Since there is always a possibilty that the glass may need to be replaced, I recommend attaching the retainers with household cement.

Choose a cement that is intended to be used with plastic and wood. Apply three small spots of cement on the edge of each retainer where the retainers contact the inner edges of the door frame. Clamp the retainers in position with spring clamps until the glue sets up. If the glass needs to be replaced, you should be able to remove the retainers with minimal damage to the wood parts.
Copyright (c) 2007 by Robert E. Reedy
All Rights Reserved

Door Installation
Page 18

Attach the Door to the Case as shown above. First, attact the hinges to the holes already drilled in the right side of the Case. Then, carefully mark the location of the hinge screws in the door. Be sure the door is centered top to bottom. Drill the holes about 3/8" deep.

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Dial Assembly Installation

Page 19

12 1 11 10 9 8 7 6

2 3 4 5

Dial Supports

Remove the Base and install the Dial Assembly by sliding it up trough the slots in the sides. Apply a little household cement to the to the inside of the slots where the Dial Supports will touch and press the Dial Supports into the slots. If there is not a snug fit, you'll need to clamp them in place until the glue sets up. Now, you can re-attach the Base to the Sides.

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Back Cover Installation

Page 20

Install the movement as per the movement instructions. Then, attach the Back Cover to the Case with #6 flathead screws as shown above.

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Broken Arch Pediment Full Size Pattern

Page 21

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved

Gr id

lin es

ar

e1

/4"

ap a

rt

Speaker Holes Pattern

Page 22

Determine the desired location for the speaker holes. Cut out the pattern and tape it to the desired location on the Back Cover. Use a center punch to mark the location of each hole. Then, removem the pattern and drill the holes with a 3/16" bit.

Copyright (c) 2007 by Robert E. Reedy All Rights Reserved