Hi everyone! I’ve been somewhat out of radio contact due to pressing work for my degree and working on a business startup….
Between then (when was the last post?) and now, the entire piece was constructed in Solidworks, had the bugs refined out (mostly avoiding work overcomplication and basic logistics), ripped apart and reconstructed. Very little has changed from the original dimensions and layout. The recipient of the largest changes were the doors in terms of the muntin/mullion dimensions (thanks for the advice on their slender weight Joe!) and glass mounting.
The material chosen for the cabinet is locally-sourced downy Birch. Whilst not going to the lengths of George Nakashima, I do like to pay tribute to the wood by not sterilising and removing it from being a natural living product. A bit of heartwood, a sound knot or inclusion here and there gives interest and maintains life in the workpiece. This is all done bearing in mind the effects of seasonal movement on wood near the heart of course. The plugs around the piece will be Ebony or possibly Pao Ferro. The intended finish is wax, specifically Liberon “Black Bison” wax in Dark Oak. I’ll go into more detail about how I work with the wax at some later point. I am leaning more towards Pao Ferro on the basis that the original seemed to use Macassar Ebony (or some other similar-looking dense wood), plus the interest in the colour variations lends more the the finished product. This is the same finish as the majority of pieces dotted around our home:
The first component out of the gate was the top. This consists of five discrete levels. The outer two form the pronounced cornicing whilst the next three produce the framing for the doors. A double dado cuts across these last three steps for the cabinet dividing walls. Mostly this was carried out on the table saw and spindle moulder with the cornices done with a hand router due to the large extension being too much for the moulder.
The outer walls were particularly forgiving in comparison to the inner equivalents. Both of these have hinges attached, and hence no internal frame angle. The two inner dividers required much fine creeping up on the final sizes to make everything fit neatly. The dry fit showed a good mate that a lick of paper will perfect.
A similar cautious approach to ensuring good mating was required of the lower carcase facings, despite these mostly being obscured by the outer skirt. The rear walls of the cabinet consist of 10mm veneer-faced plywood glued and air-nailed secure into a recess cut around the top, walls/dividers and base. At this point, the entire carcase has been domino’ed, glued; the whole nine yards.
The next step is the important one; to kick myself for not having drilled the holes for shelf mounting brackets….from here all work will be sandpaper and file to break edges and blend corners where required. Once we’re up to 240 grit, the next job will be installing the skirt and lower brackets….
-- "What can be asserted without evidence can be dismissed without evidence"