Archive for September, 2008

The Black Box

Tuesday, September 2nd, 2008

I started this job in May, expecting to finish in a month.  Early September it will be delivered.  othersideformica.jpg

This is a glueup of a two by four foot panel:  the upper mdf is getting the formica, so the glue doesn’t drip.  Overnight to dry and then the other piece.

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If you look carefully, you will see white glue squeeze-out at the ends, and grey glue squeeze-out along the black edges, which were previously formica’d.    I use PVA white glue, and purchased Acrylic Mars Black in a tube.  About five percent of the acrylic mixed into the white glue makes black glue.    How black?  This black:

blackgluedrips.jpg

These are drips from one of the glue-ups.

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The Black Box is a TV cabinet to hold a 65″ HD monitor on top, with four shelves below for electronics.  The shelves are adjustable, so I needed to drill holes for the shelf pins.

blackboxbegins.jpg

These are the ends being glued to the top.  Acute readers will notice the edge of the top has no formica.  I was trimming the long edges of these pieces (top and bottom) which are two feet by four feet on a router table.  They were too much to handle, and tilted against the trimmer bit (TWO bearings for safety) and the blades scuffed the formica.  I was pressing too hard and unknowingly tilted the panel enough to let the trimmer dig in.  I had to cut off the edges.  I will be gluing one piece over all the front edges to get a good look to the  box.

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This lets you see the shelf holes.  I purchased black sleeves and black pins for the shelves.

blackboxglueup.jpg

Here the top and bottom are connected.  The diagonal clamp makes everything square while the glue dries.  The ends got a double row of #20 biscuits 5 x 2 , the middle a single row of 5.gluebase.jpg

The base will be offset one inch from all the edges.  baseformica.jpg

Gluing up formica on the base.

shelves.jpg

Shelves under construction.

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The completed unit in place.  This is the front.  Nothing attracts dust like electronics.  You can see the black inserts in the holes. I should have painted the bottoms of the holes, but worried the paint would keep the inserts from seating.

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The back showing the wiring.  This box is holding a 65″ Plasma TV, nearly two hundred pounds.  It doesn’t budge.  I glued a full sheet on the front edges and the back.  By the end, I had cut up five sheets of 4 x 8 formica.

Hallway Bridges

Tuesday, September 2nd, 2008

Swinging bookcase

Tuesday, September 2nd, 2008

Twenty Foot Shelf

Tuesday, September 2nd, 2008