Midnight Woodworking

Woodworking

Rob’s humidor project – day 2

Last week we got the sides cut and rabbeted, so we started with glueing them up. With the box assembled, We cut the top and bottom to fit tightly within the rabbeted edges.

Ripping the top and bottom

Ripping the top and bottom

Next we rabbeted the edges of the top and bottom so that they would recess flush into the sides.

Routing the rabbet

Routing the rabbet

 

Attaching the bottom

Attaching the bottom

Rob brushed a thin layer of glue onto all of the mating surfaces, then attached the bottom plate.

Applying glue to the top

Applying glue to the top

After the top side was glued and attached, we clamped up the whole thing and let it dry for an hour.

Clamped and drying

Clamped and drying

Since we hope the cedar liner will be as air tight as possible, Rob wanted the top to be weighted to help the lid close more easily. After considering different options, I suggested that we try laminating in a piece of ipe. Ipe is an extremely dense wood. It grows in tropical rain forests, so it is pretty much impervious to moisture. I happen to have a piece of ipe decking, so we cut off a piece to use in the prototype box. Since the wood has its own natural oils, I cleaned it thoroughly with denatured alcohol. This removes the oils on the surface for a short time. Hopefully long enough for the glue to bond and cure.

Cutting down the ipe

Cutting down the ipe

 

Planing the cedar

Planing the cedar

I also have a limited supply of spanish cedar, so I re-sawed my least desirable piece for use in the prototype. Rob planed the two pieces down to 1/8″ thick, then cut a piece to fit in the top.

Cutting the Cedar for a tight fit

Cutting the Cedar for a tight fit

 

Sanding the box

Sanding the box

Before cutting the box open, Rob spent some time sanding the outside to remove tool marks and any sharp edges. He used my block plane to place a slight round-over on all of the edges, then hit the corners and everything else with the sanding block with some 220 grit paper.

rounding the edges with a block plane

rounding the edges with a block plane

 

Cutting the box open

Cutting the box open

We measured the top thickness of the box, as well as the ipe and cedar that would nest inside, then added 1/4″ to get the thickness of the lid. Setting the resaw fence up on the bandsaw to 1-1/8″ off of the blade, Rob cut the top away from the body. The top and bottom could have been built separately, but this method ensures as close to a perfect grain match as possible.

Top and bottom separated

Top and bottom separated

Flipping the box, face-down, onto a piece of sand paper, Rob cleaned off the saw marks.

Sanding the cut edges

Sanding the cut edges

He wiped the entire box down with Naphtha to clean off the dust and get a feel for what it would look like when finished.

Clean it up with Naphtha

Clean it up with Naphtha

 

Attaching the ipe and the cedar to the top

Attaching the ipe and the cedat to the top

The last thing that we did for the evening was to glue in the piece of ipe and the cedar on top of it. We used only a single bead of glue for the cedar, to allow it to expand and contract with the humidity in the box. If we had glued the entire surface, something would have cracked over time.

Clamping up the top

Clamping up the top

Rob will be getting the hardware, this week, so we should be mortising that in and installing the rest of the cedar, next week, leaving only the finishing to be completed.

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This entry was posted on April 9, 2014 by in From the scrap bin..., Misc... and tagged , , , .

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