|Project by Quietflyer||posted 02-21-2012 03:17 AM||1843 views||1 time favorited||3 comments|
My parents got themselves involved with a recorder group several years ago. They really enjoyed playing, and eventually purchased themselves some nice recorders. Dad’s came in a ratty old cardboard box with a plastic insert, and that just didn’t seem to fit with the quality of the pearwood recorder, so he asked me to make him a new case. He was just looking for a nice wooden box for the plastic insert to go into. Well, I couldn’t just stay that simple, so without telling him, I went a little overboard.
The insert is the interesting part. Since the recorder has a profile to it, I had to figure out some way to make an insert that would actually cradle the thing properly. I pondered this for an awful long time, and eventually decided on the best way to do it (short of accessing a CNC mill).
I took about 10,000 measurements of the recorder and made a CAD model of it, then designed an insert with different size bores to cradle the recorder. I then divided the model into slices (mostly 3/4 inch, but some of different thicknesses as was necessary to get the lengths of the slots right), and made all these slices out of pine, drilling the holes of the varying diameters as required. Then I laminated all the “slices” together, cleaned up the edges, and cut it in half. Opened up, it gave me two mirror-imaged inserts. I cleaned up the glue, did some very cursory sanding inside the slots, machined one long constant-size slot in the back, and flocked the whole thing with a kit from Lee Valley Tools. When I put the recorder in it for the first time, it actually fit! (well, it fit well enough anyway) I was surprised because I had to do all this without the recorder in the shop to measure from. I had to go on the measurements I had made some time before.
The box itself is super simple, just cherry with about a dozen coats of oil based poly on it. All the hardware, including the brass corners, came from Lee Valley. Two leather straps on snaps are used to hold the recorder down once its in the box.