The biggest part of this project are the panels that make up the top and sides. In case construction, panels will often be made using a solid floating panel encased in a frame of narrow boards. This framework allows the inner panel to float and fluctuate with the seasons. The other type would be just a solid panel of several boards laminated together. This project will use the latter.
The panels are constructed quite simply. I took several boards that were about 12″ wide and rough cut them down to pieces about 36″ long. Each panel used two pieces laminated together on the edges to create a large, continuous panel. I made sure to layout the pieces to decide on the best possible combinations of pieces using the best sides for each. I jointed each edge and test fit them in the clamps to be sure there were no gaps. I did this as many times as it took to get a gap free joint line. I then glued and clamped each panel making sure to clean up any glue that squeezed out.
I left these panels in the clamps until I was ready to start working on them. Mostly because I didn’t want them scraping across the floor, but also the clamps help to reduce any sort of warping. Next stage was to flatten and smooth each panel and cut it to size. I grabbed each panel, removed it from the clamps, and inspected it. I scraped away any dried glue and secured the panel to the bench. I then grabbed the jack plane and began to traverse the panel at a slight diagonal to the grain. I was trying to get it flat quickly, but also had to be aware of any tear out. Once I got it mostly flat, I moved onto the smooth plane. I had to be sure to watch the grain and I would plane in whichever direction was needed. On one side of a panel I would push in the traditional way. On the other side, I may have to pull the plane towards me.
When one side was done, I would flip it over and do the opposite side. Once I had all three panels finished, I set them aside to dry a little more and acclimate to my work space. About a week later I inspected the panels and noticed a slight cup in each. I took each panel and repeated the flattening process and set them aside again. I repeated this about 3 times total until the panels were stable and were no longer moving. My area had some rain during this time so I found that I would avoid working the panels on those days and I would work on something else.
With all three panels done, the next step was to get them cut to size. I skipped the top panel because it’s size would be slightly dependent on the final width of the carcass. The side panels, however were measured and cut to their final size. I planed the ends and edges smooth and straight and made sure each panel was square. During this process I constantly measured the two panels against each other to make sure they were identical. You could go off just measurements, but I have found that once a single piece is made, any identical pieces should be measured and compared to the original. Accuracy is key with complicated projects and this helps to reduce error.
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