Making a shadowbox table for a hero

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Blog series by Mikesawdust updated 06-17-2015 01:58 PM 8 parts 10345 reads 9 comments total

Part 1: The Plan

05-24-2015 08:55 AM by Mikesawdust | 1 comment »

A little background:I decided to make this for a wounded warrior in my unit who is being retired due to combat injuries. He’s an awesome person and does not let himself be limited by his injuries. I won’t go into specifics on his injuries, but he was an EOD operator and was in a major detonation a few years back, since then he has not only come back to full health he competed and won several command level racket ball tournaments and excels at several sports. the military believ...

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Part 2: Top and Shelf design

05-24-2015 09:18 AM by Mikesawdust | 2 comments »

I decided to go with elm and mahogany (sepele) for the main woods. I re-sawed two pieces of elm that had great figure and color. When I started to do a book match I realized that all the figure was on one end of each board and it would be out of balance on the table top. I found a simple solution by flipping one board on each end for end. and I sandwiched them between mahogany boards, I am installing bread board ends next and I decided to use Black and White Ebony Plugs in the project.

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Part 3: Black and White Ebony

05-26-2015 02:54 PM by Mikesawdust | 1 comment »

I installed the plugs in the top and shelf today, I’m very happy with the look. I used epoxy to secure them and had to be careful on the breadboard end edges to only glue the three edges of the ebony so the top can still expand and contract.

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Part 4: Making a little more headway

05-30-2015 07:26 PM by Mikesawdust | 0 comments »

Today I applied finish to the top and the shelf, I just wanted to get them as protected as possible since they can now be put away until the rest of the table is complete, I then started the legs. I went with a simple tapered leg from mahogany. I then added the black and white ebony to the tip of each leg. I plan to add more B&WE plugs to the legs during assembly and possibly some elm detail as well. I also shaped and polished two drawer pulls from B&WE, they will be install...

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Part 5: Leg joinery and plugs

06-05-2015 05:55 PM by Mikesawdust | 0 comments »

I applied made all the holes for the screws to hide under (seven per leg), applied finish to the legs and made the B&WE plugs (28). The screw holes are offset for the front and side to enable the screws to pass each other. Pillowing 28 Plugs is boring so I made a quick jig for the drill This allowed me to go through 5 grades of sandpaper on each piece over a pad. I then chamfered the bottom 1/8” of each plug with a chisel. I am near the assembly phase now. I prepped the...

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Part 6: Getting near completion

06-06-2015 07:27 PM by Mikesawdust | 2 comments »

Today I started assembly and more finishing. I installed all four sides and the lower shelf, built the shadow box top, and installed all but seven plugs. I put it together as it’s going to sit and I’m happy with the look of it. Next I will install the base, the divider for the shadow box from the drawers, the drawers themselves and hardware.

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Part 7: nearer and nearer

06-13-2015 06:54 PM by Mikesawdust | 3 comments »

Since my last post I have come a long way. I installed all the hinges for both the glass to and the wood lid and the support for the lid. I installed the glass for the shadow box (5mm). built and installed the two drawers with faces and handles. I also installed the plywood base and tray for the shadow box. First the hardware installation went well, with the exception of the lid support. The lid support was installed on the right side and needed a mortise 3/4” deep, I didn’t ...

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Part 8: Finish Line

06-17-2015 01:58 PM by Mikesawdust | 0 comments »

I have installed the last seven plugs, Installed latch mechanisms for the shadow box area, and put in the felt. The only thing I have left is adding a little finish, installing the mirror after it’s engraved, and filling the shadow box with memories of an interesting career. I will post the completed pictures when I have it ready for presentation. I hope people found the build interesting and helpful.

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