Display Case

[BrokenolMarine]

Tested the fit of the top. Looks pretty good. Will fit tight once the hinge is installed and the latches are in place. I won't apply finish until everything is done. Still need to decide on the shaping. Roll the edges, angle the edges? Decisions, decisions...

top test fit.jpg (508.48 KiB) Viewed 4064 times

[Hatchdog]

The old maker's mark is about halfway down page four for comparison.

A nice improvement indeed. It does stand out in a subtle way (if that’s possible ) on the finished piece of leather.

[BrokenolMarine]

Went to Home Depot this morning and picked up a couple things. I picked up four more hanging loops, this thing is getting heavy. I also picked up a package of special blades for the jigsaw, made especially for cutting plexiglass, after watching a couple videos on "How best to cut Plexiglass without breaking it." Who Knew they had special blades? The teeth on the blades are smaller, closer together, and angle BOTH ways, opening a channel rather than melting back together behind the cut, leaving a smooth clean cut.

NOT cheap, but after cutting this panel, worth every penny. It fits, and the cuts didn't need to be sanded or cleaned up in any way.

90 plexi cut in.jpg (735.18 KiB) Viewed 4029 times

For now, I have left the protective sheeting on the panel. It will come off later, when everything is done and I'm ready to fully assembly the case. Still have to drill some Tiny Holes to mount the plexi, mount the hinges and latches, mount the lights and the hangers. Almost done here.

Done for the day.

[BrokenolMarine]

Someone asked where I Planned to hang it. It will go here, above this table by the front door. The lamp will be gone, the painting will go, and the flag and medals will likely be moved to another location.

91 address.jpg (372.49 KiB) Viewed 4003 times

I may hang my Marine NCO Sword Above it...

[BrokenolMarine]

Spent TWO days glued to the living room, waiting for a phone call on my cell, the wheelchair service company was supposed to call. The VA sent out a contract. No Joy. My cell doesn't work in the woodshop, metal building. Guess I'll give them another chance on Monday. My lift chair I use at the Drill Press and the Band Saw won't hold a charge.

Got out this morning and repeated the original process I used to cut the frame for the lid for the display case. I cut thinner pieces from the Cherry, to use as a Retention frame for the Plexi. Won't show pics, but the process was the same. Cut the strips, sand them clean of dirt and burn marks, and in this case, I added a step. I cut a 45 degree angle on one edge with a plane, then used the sander to roll the edge over. It will be the inside edge that meets the glass. I don't like using a router unless I have to. Then, using the miter saw, I cut the prepared pieces to length to fit the frame, creating the retention frame for the glass.

92 plexi retention frame.jpg (255.5 KiB) Viewed 3885 times

The frame fit nicely, though in the pic above it's only laying on the top so it's bowed a bit here and there. When I pin it in place, it will follow the edges and line up as it's supposed to. Since the test fit worked, it's time to apply the Watco Oil and assemble the frame in preparation for assembly of the case itself.

93 Watco Oil Applied.jpg (747.56 KiB) Viewed 3885 times

I chose Golden Oak for the extra color it adds and I think it will look good. That contrast will / should make the box pop a bit, but not detract too much from the overall project. We'll see. We are nearing the end. Before applying the oil, I sanded the rough corners to get rid of those little tits sticking out and sanded those plugs just to insure they were perfectly flush. We should be golden. (oak) Sorry, couldn't resist.

[BrokenolMarine]

We have Glass...
Next up, hinges and lights.

94 we have glass.jpg (501.92 KiB) Viewed 3837 times

[BrokenolMarine]

Have been busy of late. Yesterday I sanded the wax off the sides of the case and stained it a bit darker. I used dark walnut watco oil and was happy with the outcome.

95 darkened case side stain.jpg (485.31 KiB) Viewed 3754 times

[BrokenolMarine]

Back out today, and first job was to attach the piano hinge to the top. Clamped the hinge in place and drilled the holes to a marked depth. I marked the bit using painters tape, and vacuumed away the sawdust to protect the plexi from scratches.

Each screw was waxed by screwing it into a wax block then backing it out.

96 waxed screws.jpg (364.01 KiB) Viewed 3754 times

Each screw was carefully and slowly screwed into place using the drill, but was torque set to break when seated to avoid breaking off the head or cracking the wood.

97 torx driven.jpg (431.47 KiB) Viewed 3754 times

Got the hinge attached without mishap. An accomplishment not always possible. Easier with steel screws rather than brass.

[BrokenolMarine]

This next step was a high pucker factor. It involved drilling down thru the quarter round to pass the lighting wiring thru to the back of the box. I suspected the brad bits would work best, so I decided to test the theory on the scrap quarter round. I drilled the 3/8 hole in the quarter round, then cut a few 3/8 plugs from the same... I notched the plug for the wiring and tested the fit.

98 cut the slot.jpg (461.93 KiB) Viewed 3754 times

This worked well. The wire nested in the slot and the plug fit. But, how would I trim the plugs flush with the wires running thru them without risking cutting thru the wires. Ah... use the test pilot hole as a jig... and cut all the plugs flush in the jig then push them back out. Luckily I remembered to cut the slots for two on the left and two on the right.


Mounted the JIG in the vise....

100 used the scrap as the jig.jpg (568.01 KiB) Viewed 3754 times

101 trimmed each flush.jpg (455.52 KiB) Viewed 3754 times

Worked like a champ.

[BrokenolMarine]

I mounted the four lights and ran the wiring through the holes I had drilled with the brad bit, holding my breath....
Then pushed the plugs into place. Looked good.

102 four lights installed.jpg (439.56 KiB) Viewed 3754 times

The plugs looked pretty good, I had pre-stained them to keep from getting stain on the wires.

103 plugs worked as planned.jpg (430.87 KiB) Viewed 3754 times

The box is looking pretty good. I need to screw the hinge to the box itself, attach a latch, and then the french cleats. Nearly done.

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