|Project by ferstler||posted 12-09-2010 01:14 AM||2254 views||15 times favorited||18 comments|
This is actually a Christmas present for my wife, and so she has not even seen it yet. I got the idea from seeing something at a crafts show recently, but I wanted to do my own take on the item.
The lid is select pine and was done quite simply with table saw, miter saw, jointer, planer, table-top shaper, and lots of hand sanding. There are six coats of satin-finish enamel on the piece. The knob was a store-purchased item.
The bottom section is in two pieces. The black part (four enamel coats this time) is select pine and was done about as conventionally as the lid. The stained part (douglas fir) was done separately, and that involved the most work. First, after cutting it to size I drilled out the holes using several forstner bits. Then, I rounded off the cuts at the tops using a roundover bit and a bench shaper. I also used a rabbit bit to very slightly (1/32nd inch) undercut the bottoms of each drilled hole. More on that, below.
The two pieces were glued together and once the glue was dried I used a planer, table shaper, and lots of hand-sanding elbow grease to smooth things over. The assembly (including the black enameled part) was then given four coats of clear satin polyurethane. Three small oak dowels were installed in the top of the bottom part, with corresponding holes in the lid to allow it to be properly aligned when installed. I used pins instead of hinges, because I wanted a clean look all the way around with the lid on.
OK, so why did I undercut the bottoms of the drilled holes? Well, the unit I saw at the crafts show had each hole bottom covered with thin felt pads. However, the builder could not cut them perfectly to size, and so you could see the irregularities at the bottom. My solution was to undercut the hole bottoms before gluing the two pieces together and then cut the pads for the bottom very slightly oversized. That way, they could be fitted into the recessed areas all the way around for a clean edge as dictated by the circle cuts themselves.