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Blog series by Lee Barker updated 11-28-2011 09:19 PM 4 parts 4424 reads 3 comments total

Part 1: Carcase together

11-28-2011 08:50 PM by Lee Barker | 0 comments »

This project was designed from the inside out: Center channel speaker, subwoofer (left hand side lower), two bays for components (flanking the center channel) and of course Mr. Plasma. He was the most critical: The client requested 3/8 clearance sides and 1/4 top and bottom. The screen is to hang on the back wall of the cabinet, so it had to be 3/4 thick and inset. Cable management, though not as demanding as in the past, was a constant consideration. The main speakers sit in the open...

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Part 2: Top details, ready to finish

11-28-2011 08:57 PM by Lee Barker | 0 comments »

Originally we planned a top that would drop on; progress meetings landed on crown moulding. This required a 3/4 thick top with a solid stock edge, accomplished with a few clamps. The crown was purchased locally and was quite dark. Fortunately the decision was to go with just varnish, so it all will darken eventually. There was considerable anxiety concerning the time involved, which boiled down to questions like they get at the ski slope: “When will it stop snowing?” ...

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Part 3: Finish applied

11-28-2011 09:04 PM by Lee Barker | 0 comments »

I used Pro-Fin on the flat surfaces that I could do separate from the piece. For the assembled carcase, I used Minwax Wipe On. Sanded between coats, used a bright light and a really expensive brush (Gramercy) to apply it. It came out quite well. In the cooler weather I had to allow more time for curing. The piece has been delivered and the electronicals installed. When the dust settles, I’ll get back to the client and get a portfolio shot.

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Part 4: The mystery of the felt pads where the cabinet meets the floor

11-28-2011 09:19 PM by Lee Barker | 3 comments »

This was of great concern to the client, who kept a somewhat (understatement) close watch on things. When we rolled in the carcase on the two platform dollies, he asked if the felt pads were installed. “No, I’ll do that here,” I said. He allowed as how he’d really like to see how I did that. My helper left. To my delight, a long phone call kept the client away while I brought in my HF 1 ton floor jack. I just cranked up one end, removed the temp blocks, and stu...

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