|Project by Caleone||posted 04-02-2015 02:27 PM||2870 views||5 times favorited||20 comments|
I just completed these bookcases, not only my first furniture-quality casework (outdoor and shop cabinets don’t count, right?) but also the first time I have tried to do “production” work, making three identical bookcases simultaneously.
The cases are 3/4” maple veneer plywood, All the trim is solid maple, the shelves and supports are solid (12”) maple set in dadoes cut into each side, and the backs are 1/4” maple veneered ply. I purchased PureBond Project Panels for the case and backs from HD, which I will never do again, as the shipping costs were outrageous and the quality of the product extremely poor: whisper-thin veneers, crushed edges and corners, no wood plys in the core. The cost of the panels plus delivery well exceeded the cost of A1 plywood special ordered from the ‘true’ lumber yard 12 miles away, and cost-comparable to furniture grade maple ply from the specialty lumber supplier 28 miles away, so next time around I will burn the time and gas to go buy the better product. Shame on me.
I purchased the slabs from a local sawyer who told me the Bigleaf Maple (acer macrophyllum) was salvaged from a riverbed. I rough trimmed the slabs, straightline ripped to width, and in the case of the clearer slab, moved a part of my offcut down from an oddly shaped and heavily voided part of the board and edge joined it to get the width and overhang I wanted. Then I filled all the voids and cracks with epoxy and/or stabilized with walnut butterfly keys. Surfaced, natural edges polished, and trimmed to final length with 20 degree bevel cuts.
The case and shelves are finished with one application of Danish Oil and two applications of oil-based polyurethane, wet sanded at 320 in between. The slab tops are finished with one application of Danish Oil, two with oil-based gloss polyurethane, and then three applications of satin polyurethane. I wet sanded each application at 320, then buffed the top with a 6000 grit microfiber pad. I am pretty happy with the overall results save for the unknown longterm performance of the ply material. I hope you all like it—remember, this is the first time I have made anything like this, and my first venture into the deep waters of Lumberjocks. Caleone
-- Caleone, Sammamish, WA