|Project by GnarlyErik||posted 03-12-2013 03:06 PM||2132 views||1 time favorited||11 comments|
This little item was made for my daughter’s recent birthday. It is a simple hinged clamshell, lined with ‘spray-on flocking’ – my first attempt at that, which was really quick and easy.
Each half of the clamshell is made of five ‘lifts’ of varied woods, each about 5/16” thick. Beginning on the outside is mahogany, then butternut, cherry, maple and padauk. Each lift except the outer one, were first rough ‘hollowed’ by removing the centers with a scroll saw to save on chisel work, then glued together. The lifts were kept in proper alignment for glueing with a pair of nails in holes drilled through excess material deliberately left on the hinge sides. When the glue set, each half was then rounded with a plane and spoke shave and finished by rounding and hollowing with a Dremel flex-router tool and chisels by hand – which took far more time than I had figured, especially the hollowing part. The rounded shape was a real challenge to clamp in position and special wooden chocks were needed to grip things.
The two pieces were then finish sanded and received five coats of varnish, then assembled with a simple 2-1/4” hinge. A small foot was added under the hinge under the bottom half to steady the clamshell when opened. The clamshells end up about 1/4” thick, and the entire assembly is surprisingly light in weight.
This was a bigger challenge and took far more time than I anticipated, but my daughter loved it in the end! I don’t think I will do another.
-- "Never let your dogma get run over by your karma!"