Many of you saw the beginning of this project because of an issue I had cutting grooves for the spline joints.
http://www.shopsmith.com/ss_forum/gener ... 16398.html
Plans from Woodsmith #59, I increased the overall size about 20%. The stock is red and white oak and the bottom is mdf core cherry pw, and the splines are from a reclaimed piece of furniture (I think rosewood?).
This project is a wedding gift and I wanted to personalize it. I tried using a scroll saw and router, but was unhappy with the results so ended up going to a laser engraver.
The finish was BLO and clear spray lacquer from a rattle can.
I used the SS and SS band saw for all the cuts. The round overs and rabbets were done on a router table.
- JZ finish 289.jpg (69.16 KiB) Viewed 2889 times
- JZ finish 290.jpg (81.16 KiB) Viewed 2889 times
- JZ finish 291.jpg (63.8 KiB) Viewed 2889 times
I thought I just mention the cutting of the bottom. After completing the glue-up of the sides, handles and corner pieces, using a rabbeting bit, I routed a 1/4" x 3/8" rabbet on the bottom edge going around the inside perimeter of the tray. Here's a pic of the tray up-side-down so you can see the rabbet.
- JZ 010259.jpg (49.73 KiB) Viewed 2889 times
Then I "sandwiched" and held together with double sided tape: a) the oversize cherry pw bottom; b) an oversized 1/4 hardboard for a template; c) the glued up tray. With a flush trim bit, guiding against the outside edges of the tray, I cut both the template and the bottom to the same exact size as the tray. (The tray is removed in this pic for clarity)
- JZ flush trim 264.jpg (40.76 KiB) Viewed 2889 times
I removed the tray from the "sandwich" and switched to a rabbeting bit with a guide bearing sized to cut the bottom to fit. Made the cut guiding against the template edge and cut the bottom. These pics shows the bottom and template, still taped together, where you can see the cut on the bottom and the bit used.
- JZ rabbit 269.jpg (41.86 KiB) Viewed 2889 times
- JZ rabbit 268.jpg (64.39 KiB) Viewed 2889 times
- JZ btm view 270.jpg (41.71 KiB) Viewed 2889 times
Here's a view of the engraving
- JZ laser 276.jpg (75.65 KiB) Viewed 2889 times
Anyway I hope this makes sense. Thanks for looking.
