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.


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:


These are drips from one of the glue-ups.


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.


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.


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


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 under construction.


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.


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