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Wall Unit Project #6: Doors and the Mosaic Panel

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Blog entry by DS posted 492 days ago 1147 reads 0 times favorited 12 comments Add to Favorites Watch
« Part 5: Welding and Wiring and Shelves, Oh my! Part 6 of Wall Unit Project series Part 7: Top Shelf and Doors installed »

With the shelves done, I need to make and install the mosaic panel before the top shelf can be installed above it. The panel will be on french cleats and will be locked into place by the top shelf.

Since I am working with a large number of 23” X 41” panels, I am having to assemble the 58” X 64” mosaic backer panel using several smaller parts. This will all be hidden by the mosaic veneers on the face, so it only needs to be flat and strong. I managed to re-use all the offal from cutting the doors.

I chose to use 5/16” dowells to ease the assembly of the panel. I did it in three rows, which I assembled first, then glued the rows together.

Here, you can see the last row in the clamps.

While the glue dries I can get busy with the doors. I previously sized them, cut the centers out on the table saw and edgebanded the outside.

I need to add edging to the inside edges that will receive an inset fabric panel.

I’ve found that the gel formula contact adhesive works really well with these small foam rollers you can get at the HD store. By ganging the doors together, I can roll adhesive on all the edges at once.

Maple thintape veneer comes in large rolls and I have plenty leftover from previous jobs.

The doors are now edged, trimmed and sanded – nearly ready for finish. I’ll probably drill for hinges and prefit them on the cabinets before final finishing. I purchased the fabric last night on the way home.

The last row is just sitting next to the rest of the panel. It will have to wait for later to get attached.
The mosaic pattern is still TBD… at least for a couple more days.

——————————————————————————————————————————————-

More progress on the doors!

Marking and drill for Blum CLIP hinges.

A 35mm forstner bitin the drill press drills the main cup hole.

A 5/16” drill bit drills the dowell/alignment holes.

Honey Maple smooth coat finish.

Fabric panel inserts are next!

-- "Hard work is not defined by the difficulty of the task as much as a person's desire to perform it.", DS251



12 comments so far

View Joe Lyddon's profile

Joe Lyddon

7620 posts in 2650 days


#1 posted 492 days ago

Hey!

You’re making super progress!

Thanks for the update!

Take care.

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View oldnovice's profile

oldnovice

3596 posts in 1966 days


#2 posted 492 days ago

You are a busy man! Looking good, is the mosaic going to tile or wood?

-- "I never met a board I didn't like!"

View DS's profile

DS

2131 posts in 1018 days


#3 posted 492 days ago

I’ve accumilated several veneers that I will stitch into a pattern for the face.

The issue is what, exactly, the pattern will look like. There are several ideas floating around between my wife and I, but, as of yet, no concensus.

-- "Hard work is not defined by the difficulty of the task as much as a person's desire to perform it.", DS251

View stefang's profile (online now)

stefang

12571 posts in 1932 days


#4 posted 492 days ago

A lot of work, and all well done. Looking forward to the finish.

-- Mike, an American living in Norway.

View SASmith               's profile

SASmith

1546 posts in 1585 days


#5 posted 492 days ago

I can’t wait to see what pattern you come up with.

-- Scott Smith, Southern Illinois

View SPalm's profile

SPalm

4753 posts in 2480 days


#6 posted 492 days ago

Neat. Looks great.

Interesting way of making doors. But hey, you use the material you got. Good for you.

Steve

-- -- I'm no rocket surgeon

View JL7's profile

JL7

6994 posts in 1563 days


#7 posted 492 days ago

Very interesting DS…..not entirely sure what’s going on, but I’m certain it will be cool…..

-- Jeff - I have not failed. I've just found 10,002 ways that won't work.

View DS's profile

DS

2131 posts in 1018 days


#8 posted 491 days ago

Steve, these are technically slab doors. I routed a rabbit into the inside back edge last night to accept the fabric panels.

The entire point of this project is to use the material I’ve got. Normally, I would make a solid frame door. But, here I have all these lovely Maple panels to use up. And we wanted a very contemporary wall unit as well, so that lends itself to the slab construction.

I began drawing the mosaic pattern on the substrate panel last night and the wife actually stated she might like it, so there is a chance to get busy on it soon.

-- "Hard work is not defined by the difficulty of the task as much as a person's desire to perform it.", DS251

View DIYaholic's profile

DIYaholic

12900 posts in 1273 days


#9 posted 491 days ago

Nice progress report!
Please be sure to let us know what the final decision for the mosaic will be!
We need to know what SHE decides, err the consensus is!!! ;^)

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View Dave's profile

Dave

11142 posts in 1438 days


#10 posted 490 days ago

Looking good. Keep it up, you are getting closer.

-- Superdav "No matter where you go - there you are." http://chiselandforge.com

View DS's profile

DS

2131 posts in 1018 days


#11 posted 490 days ago

I’m pretty sure she’s signed off on my latest design.

That may get vetoed part way through it if she later decides she doesn’t like it.
We’ll see.

I started putting finish on the doors last night but didn’t get much shop time due to family in from out of town.
They got sealer front and back though.

-- "Hard work is not defined by the difficulty of the task as much as a person's desire to perform it.", DS251

View DS's profile

DS

2131 posts in 1018 days


#12 posted 489 days ago

I’ve updated with photos from last night’s progress.

-- "Hard work is not defined by the difficulty of the task as much as a person's desire to perform it.", DS251

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