Friday, June 20, 2008

At last! With handles made from scrap rosewood smuggled back from a Costa Rican surf trip, the mirror box is easily mounted and ready to use. Its dimensions are: 43" wide, 42" tall, and 11" deep.
To see the progress of this project from the beginning, scroll back a mere 28 posts.

With the finishing complete, it's time for final assembly. Here I'm attaching the box frame within the notches of the runners. Later, the curvy supports that go below the box frame will attach to the frame and runners. The hook bar will then attach to the supports. Finally the mirror is attached to the runners as well.

A first coat of linseed oil for the mirror frames.

With all of the elements built, fitted, and sanded, it's down to finishing and assembly. Here the boxes get a coat.

With the notches complete, the outer edges of the runners get a small bevel or "chamfer" with the spokeshave.

All cherry elements attach to the wall via two maple vertical runners. Here they receive notches with the dado blade that the box frame will sit within.

With the mirror frames fitted and glued, the mirrors and backing boards need notches within which to rest. A great job for the router.

Transferring the joints from the vertical members of the mirror frames to the horizontal with a drafting pencil. Cuts are then made with table and bandsaws.

Giving the dovetails that hold the mirror frame together a bit of style.

The box frame sits on supports that will attach to the wall-mounted runners. With the bandsaw, giving them a bit of curve is easy.

Once the glue has dried, all surfaces must be sanded smooth before finishing.

After many hours cutting, shaping, sanding, and fitting forty vertical supports from walnut, the shelf/ box frame gets glued. A total of sixty small surfaces are being glued at once. Speed and accuracy are critical.

Using dado blades (multiple table saw blades sandwiched together to bake a wider cut) the notches are cut in the top and bottom of the box frames. These cuts are made to accept the vertical walnut parts that give the box frame structure. Look for the already notched boards behind me.

No turning back now! With all mating surfaces covered in a thin coat of glue, I have to work fast before everything sets up permanently.

With all edges snug and correct, all that remains are the box bottoms as well as cutting the notches to accept them.