These are the small scale drafts for the two cases. One will be a four glass door case and the other a four section shelf. Both are about 11' wide, 5' tall and 1' deep.
Here's the shop drawing to show all the joinery in the case. I've created a stock list (bottom left) from this drawing that I'll use to buy lumber.
Fresh from the lumber yard! 180 board feet of quarter-sawn white oak. This is enough material for everything minus the shelves. I'll buy that once the cases are built.
The book case will be built first, then the bookshelf will follow. These are the rough milled parts for the bookcase body.
I'll be using hide glue throughout the process on both pieces.
The side panels are being glued up now. They are still over thickness and will be milled down to 1/2" once the glue dries.
This is the crosscut sled I use to cut pieces to length. The long adjustable L stick allows multiple pieces to be cut to the exact same length.
Each surface is planned to remove any mill marks and leave a smooth finish.
My bench is the perfect length for this project!
The center posts have a 1 1/2" wide body with a 2 1/4" wide foot which will later get tapered. This is the setup I used to cut the 3/8" off each side of the post. Once the first cut was made I went and temporarily glued blade kerf-sized shims in between the post as the cutoff. This allow the second cut to be made with the same fence setting, keeping the post symmetrical. The shims were popped off after the second cut was made.
The off-cuts break off and the remaining wood will be chiseled and scraped flush.
The four outside posts have grooves cut into them to accept the floating panels. The side rails also have these grooves cut into them.
The top center cross-member is a dovetail joint that will drop down from above to join the front and rear center posts.
Cutting the dovetail socket into a center post.
Here the joint is dry fit snug. This will be glued in permanently later on.
Here are the center posts with the dovetail joints dry fit together. There will be a twin-tenon cross member on the bottom of the feet. The feet will also get tapered once the front rails are cut and fit.
I'm sizing the joints. This is the process of applying a diluted cut of hide glue to the joint beforehand and letting it dry. The theory is that this dilute cut will sink deep into the pores of the wood and act like the roots of a tree once the full strength glue is applied and the joint is clamped together.
Now it's time to mill the wood for the door stiles and rails. All of the wood will come out of three boards which are prefectly quarter-sawn and very straight grained. The horizontal rails are cut up and I placed them back together to show how they will be aligned. Planning out the layout of these parts carefully will visually unify the bookcase. The vertical rails and stiles will also come from consecutive boards to unify the piece even further.
The ship-lapped back will be made out of bookmatched 5/4" resawn boards. This will allow me to make the entire left half of the case back perfectly symmetrical to the right half. Here Jonathan is helping in the resaw of a wide 12 1/2" wide board.
Here's the back material, still over thickness.
The backs have been milled to finish thickness and now I'm rabbeting the edge of the ship-lapped backs. The fence setup holds the pieces down to ensure the rabbet depth is even throughout the cut.
I'm using my trusty #80 cabinet scraper here to remove the mill marks from the back. After a proper sharpening the scraper plane is working better than ever!
This is a piece of 3/16" MDF I've cut up and drilled holes into to use as a template for the shelf peg drilling process. I will register the bottom end of the template at the same elevation on each piece to be drilled to ensure the holes line up and the shelves are flat.
Once the first hole is drilled one of the pegs is placed to register the template. Three more will be places even spaced throughout, then the remaning holes are drilled.
One upright is finished and two pegs are in place. All of the holes will be as hidden as possible. The holes for the fronts of the shelves will be drilled on the backside of the uprights. The holes for the backs of the shelves will be drilled on the sides of the uprights.
All 528 of the 1/4" round holes have been drilled!
All the mortises for the case frame and door frames (shown here) have been cut and it's time to cut the tenons to fit. Thanks KPW for the time on your mortise machine!
A closeup of the said mortises.
Here I've cut and fit the twin tenon on the bottom of the center posts.
The legs are getting tapered on both inside faces. To achieve this I cut close to the line on a bandsaw then cleaned up the marks with a hand plane, making sure to stay 1/16" away from the rail mortise.
Using this hold down on the cross cut sled I'm cutting the tenons for the case frame. The blade height is changed for the front and back cuts of the tenons because they are offset.
Here I've made a sample board for the finish on the case. The four different sections are different ratios of Transtint Brown Mahogany dye (1:16, 1:32, 1:64, 0:0), then a sealer coat is applied. After that dries a glaze is applied to color the pores of the wood. The final step is three coats of Waterlox Satin varnish.
I've cut the side panels to dimension and now I'm cutting the bevels on the tablesaw. Since the saw I'm using tilts to the right I had to move the fence to the left of the blade (the fence is hidden behind the panel right now.) Once the bevels are cut I'll clean up the saw marks with a handplane.
The side sections are dry fit and won't get glued up until the panels are finished.
The center section is being glued up here.
Now that the tenons are cut and fit on the front rails I can go ahead and shape the curves. Here I've cut just outside a pencil line made with the MDF template on the top.
Now I'm using a flush cut router bit to run off of the MDF template to cut the apron to the exact size.
And the mill marks are removes with a spokeshave.
Half of the case is dry fit here. I've done this to double check the measurements of the doors before the door joinery is cut and fit.
The bottom rails on the sides have an arc cut out of them. I forgot to cut this before gluing the rails to one of the posts, so I cut them afterwords using a template and a flush cut router bit. I couldn't cut right to the edge, so some hand work using a gouge and rasp was necessary.
The case rails and center dividers are being glued up first. I'm using my bench tail vise for this.
The door rails all have their tenons cut. The haunches will be sawed and chiseled out by hand.
The joinery has all been fit and now I'm gluing them up!
Here's a quick sketch of how the glass will be attached to the doors. The retaining strip will have a bevel cut so the screws will pull the strip against the glass, eliminating any rattle.
To cut the bevel I've made an angled channel in a scrap piece of wood. The whole assembly will then get sent through the planer.
Here's the retaining strip all cut and finished. The jig used to cut the bevel will also be used when drilling the holes for the screws.
Here are the doors and the case rails & dividers all glued up.
To cut the rabbets to receive the glass panes I first used a rabbeting router bit, bearing against the bottom 3/16" lip shown here.
Next the top lip is removed with a flush cutting bit.
Finally the corners are chiseled square.
The glass is in! Tempered 1/8" thick panes are used.
The process here is to install each pane with the retaining strips screwed in place, plane and sand the strips flush (as seen here), remove the strips, label them and put them aside for finishing.
Using a few simple raw materials I will make a pull, and if the client like it I will make three more.
The surface of the 1/8" plate is textured with a ball-peen hammer. A 3/8" wide strip of 1/16" brass is bent over to accept a swinging hinge.
Each door will have a lock. I've drilled the hole for the keyhole and here I'm using a jewelers saw to cut the rest of the shape out.
To keep the pull from being able to spin around the main bolt I've soldered a small brass pin underneath the hinge strip.
The glass retaining strips are being finished! Here I've applied two coats of water-based dye followed by (once it's dried) an oil based sealer.
The side panels have been finished and now I can finally glue the sides together.
Here are the four brackets used to hold the case together. It will be disassembled for delivery and installation and these stainless steel brackets will be installed on site.
Clamps hold the case together while I drill and install the brackets.
Back to the pulls... I've hammered texture into the pull, bent it to shape and now I'm soldering it together.
Installing the backs!
The rabbet has been cut on the back side and the back panels are being installed. You can see the top two brackets installed in this photo.
The backs are all installed.
Ledges with pre-drilled screw holes have been glued into place on the bottom rails in order to attach the case bottom.
Pocket holes are chiseled out on the top rails to allow the top to be screwed to the frame.
Here's a view from the inside.
Fitting the doors into their respective places. An even reveal of about 1/32" will be planed away.
Now the door fits in the space the hinges are to be installed. To center the hinge barrel I've measured the thickness of the barrel, deducted the reveal amount (1/32") and divided that number in half. This depth (.011") is how deep I will cut the mortise for the hinge on both the door and the cabinet frame.
There it is! I've installed the glass to see how, if at all the door would sag. It was a negligible amount.
Two down, two to go.
Using brass darkening solution I've darkened the #1 screws used to fasten the glass retaining strips to the door. I'll also be using the same solution to antique the pulls.
The door stops will have leather applied to the contact surface.
The leather has been glued on and the stops have been ripped.
The leather is trimmed and the stops are ready to be glued in place.
Here the stops have been glued on and the bullet catches have been installed.
Each decorative cleat is installed with two screws; one going into the top from the backside of the cleat and another going into the cleat from inside the case. The pocket holes are cut on the backside to allow the screw to secure properly.
A shot of the cleat installed. You can see the hole for the recessed screw in the rabbet of the ship-lapped back. The screw hole for the front cleats is hidden behind the top hinge.
The view from the front.
Now all it needs are shelves and finish!
Here's the rough stock for the shelves. The lumber yard (Highland Hardwoods) had some great wide stuff they pulled out for me. It's not often you come across 12" wide quarter-sawn White Oak!
Since it's important these boards are dead flat I'll be running them through the milling process with one extra rough mill.
I couldn't help but make something out of the cut-off scrap from those great wide boards. Usually it becomes firewood but these pieces were longer than most scrap. My toolbox is a bit cramped and it would be nice to have a box just for carving tools...
And a box for carving tools needs to have carving on it. This panel will be the drawer fronts. It's two thin-blade kerfs oversized right now. I'm about to rip it into three drawer fronts...
There it is! Time to make the drawers. In the spirit of this side project all of it will be made from scrap, which means solid quarter-sawn white oak drawers, bottoms too.
The shelves have been finish milled and the notches have been cut.
There it is! I still need to remove the mill marks on the shelves, chamfer the inside corners of the front feet and ease all of the edges. I've replaced the top back board with one that extends to the edge of the top board. The original design had the back board set in about 3" on each end and the client and I agreed it looked a bit off.
#80 be my strength! This puppy takes some great shavings when it's been freshly sharpened.
I've disassembled the case and knocked it over to chamfer the inside corners of the front feet. This will lighten up the look of the feet.
The end is near...
The ingredients for the stain. 3 parts Brown Mahogany TransTint, 2 parts Red Mahogany TransTint and 120 parts distilled water.
The board on the right hasn't gotten the glaze yet. You can see how much the pores darken afterwords. It really adds dimension to the wood.
Waiting for finish to dry is the perfect time to finish up my side project.
Here's the progression of finish products... First distilled water to raise the grain followed by a sanding, then to coats of Transtint, a coat of oil based sealer, a coat of walnut colored glaze (gel stain), three coats of satin Waterlox, and finally a polish with paste wax.
Everything has one coat of Waterlox. Just two more to go!
The shelves with finish and sunlight.
Here we have the prototype pull on the left and the four final pulls in pieces on the right.
The differences between the two are the width is 1/8" less, the ring is smaller and it is placed 1/8" lower. The keyhole will get cut into the brass eventually.
The hardest part of this whole process is bending the ring without breaking it. To achieve this I've created a steel form in the shape of the inside of the ring. The small bar welded to the top holds the brass in place for the first bend. I use an oxygen/acetylene torch at a very low temperature to heat the brass to a dull glow when bending. I went through and broke six rings trying other methods before I came to this. Each ring has about one thousand hammer blows to give it texture, so breaking one can be a bit frustrating.
After the form the brass looks like this.
The excess is cut off with a hacksaw and then silver soldered together.
The piece is almost finished! It just needs pulls and locks.
The hardware wasn't secure enough and still wiggled, so I've soldered a second thread onto the backside and drilled the respective hole into the doors. The nut will hide underneath the lock.
Here's the second half of the two part mission case project. This is going to be a bookshelf with no doors or back. It's all there, I just need to remove the right amount of wood from the right places.
It's done! Quite handsome I do say.
I'm really pleased with how my first ever home-made hardware turned out.
Up close.
The bookshelf after final milling. The shelves are in the background still oversize.
The mortises for the stiles have been cut.
Using an arc shaped template (dark MDF) I'm cutting the curved shoulders on the stiles.
The stiles look like this afterwords.
A nesting template will be used to cut the curve in the rails.
The rails being cut...
The underside of the bottom rail has the same arc cut in it.
Here's one of the five panels all put together dry. The mill marks still need to be planed off the rails and stiles before I can glue it up.
Just to see how it will look...
The dado's to receive the shelves have been cut.
The rear posts have through dado's cut (left) while the front posts have stopped dado's which need to be chiseled square.
Making a sample board for the shelves... The middle rectangle will be the same as the bookcase while the surrounding spaces will be more brown, more red, more dilute and less dilute.
The top shelves have dovetailed housings up front to hold the case together. This ramp block is used to accurately cut the angle of the housing walls.
I'm using the router plane to flush the bottom of the dado with the rails.
To fit the shelves into the dados I'm measuring each edge at three points, then planing the underside of the edge so it is exactly .745" thick.
All fit together dry.
a 1/4" x 1/2" notch has been cut in the front corners of each shelf...
...and the shelf comes 1/8" set back from the front post.
The first coat of stain. This time I'm using a ratio that has more brown and less red dye than the bookcase.
And the second...
Followed by a coat of oil based sealer.
So I don't forget...