|Forum topic by intjonmiller||posted 06-16-2016 08:56 PM||651 views||0 times favorited||4 replies|
06-16-2016 08:56 PM
My sister-in-law asked me to help her make a shelf for their new TV components setup. To match other things in their home, including things I’ve made for them, they want to use knotty alder. But the price (online only) for knotty alder corbels of the size she wants is prohibitive. So I need to figure out how to make them.
This is the style they like, which they found by actually looking at it in person in Home Depot: http://www.homedepot.com/p/Waddell-WADCR323-14-in-x-7-1-2-in-x-5-in-Basswood-Mission-Corbel-10001543/205977521
Would you start with solid wood (well, laminated for that thickness as I’ve never seen larger than 12/4 alder at either of my suppliers) and carve/route away the excess, or would you add the details as separately milled moldings? I’m open to either approach, but I think I favor the separately milled approach.
In the latter case, how important (both for style and stability) is grain direction? Those details would be much easier to manage with the grain running perpendicular to the main body.
Open to other suggestions as well. This is well outside my expertise, but I’m interested in it as a learning experience. For reference I have a table saw, table-mounted router with INCRA router fence, decent set of router bits, RAS, handheld routers with fixed and plunge bases, and a basic set of planes and chisels (no other carving tools). My brother has a 14” bandsaw I can use, but he only has one blade (I forget the width, but not usable for tight curves, just broad ones). Accomplishing this without buying more tools would be ideal. :)
I also have a brother-in-law with a 2.5 axis Biesse CNC (3-axis capable, but he doesn’t have the CAM software for that). In theory that could be used, but we’ve never used it for anything but sheet goods. Seems impractical to make that work for this project.