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David
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Discussion Starter #1
Starting a new project for a serious audiophile with some serious equipment. His McIntosh amp alone weighs 125 lbs.! The dimensions alone make this rack impressive; everything is 8/4 and the shelves are 23" deep, 52" wide, and the unit is 31" high. Each shelf will weigh about 70 lbs.

The top shelf is Curly Maple and the middle and bottom shelves are Northern Hard Rock Maple. These will be banded with Curly Maple so from the front you'll see Curly Maple shelves. But since the middle and bottom shelves will be covered with gear there was no need for these to be the much more expensive Curly Maple.

The legs are about 2" x 3" and are Purpleheart. I'll finish the piece in Nitrocellulose lacquer.

While there's no rush on completing this piece I do want to stay on it as much as possible but as other orders come in I'll put this aside. For instance, we got two separate orders for 18" Longworth chucks today so I'll move all of this out and cut the chucks tomorrow, then move all of this back in to begin planing and jointing shelves.

When the shelves are glued I'll take them to my friend's cabinet shop and run them through their wide belt sander. Our SuperMax 19-38 will work but it will be so much easier to do it on their wide belt sander.

As you can see, just the lumber alone overwhelms our little shop and when it comes to assembling this I'll have to do it in the house because I don't have room in the shop to put it together. :wink:

Preliminary design -
001 - Curly Maple and Purpleheart audio rack.jpg

One shelf, basically, prior to jointing -
002 - Hard Rock Maple for shelves 23 x 52.jpg

All the lumber for the project -
003 - Curly Maple, Hard Rock Maple, Purpleheart for audio rack.jpg

Curly Maple close up shots -
004 - Curly Maple for audio rack.jpg

005 - Curly Maple for audio rack.jpg

More photos and updates as I work through this project. Enjoy!
David
 

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David
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Discussion Starter #3
It may not seem like much progress but I have now cut to length and planed all of the Hard Rock Maple, straight lined the edges of all boards on the tablesaw, and run every edge on the jointer. These boards are heavy and I'm worn out!! LOL!

Running the Curly Maple on the jointer was a bit iffy since I have straight blades but they are razor sharp and I took very light passes. The edges came out very clean with very minor tear out in a couple of places but they're in the middle of the edge so it's not going to be an issue. I considered getting a Shelix head for the jointer - PM 54A - but since this worked I'll do that upgrade later (maybe).

I have another project I need to move to this afternoon and that may prevent me from gluing these boards today to get the 23" width but they're ready for that step.

006 - Planed, ripped, jointed, ready for gluing.jpg

007 - Curly Maple edges.jpg

More later!
David
 

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David
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Discussion Starter #4 (Edited)
Minor update on this audio rack; turns out the straight knives on my jointer were not giving me the clean edge I thought I was getting on the Curly Maple. When I moved the boards into different light and looked at them closer I saw the tear out in a few places. I made some changes and ran them again but with the same results.

So, today I ordered a Shelix cutterhead for my PM54A jointer. For now this project is waiting on the new cutterhead. I have wanted one for a while and never wanted to spend the money but this project is worthy of an equipment change. Besides, any project that requires the purchase of a new tool is a good project - right!!

009 - Curly Maple - edge chipped.jpg

010 - Curly Maple - edge chipped.jpg

David
 

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David
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Discussion Starter #9
Ok, I'm back on the audio rack after installing the Shelix cutterhead in my jointer over the weekend. Today I cleaned up the edges on the three Curly Maple boards, one pass each. Because I bought the cutterhead with bearings installed and 15 extra knives the cost with shipping was $400 and it took about five weeks to arrive (backordered). So that's about $67 per pass but wow do the edges look good! :grin:

Here are the chipped edges -
009 - Curly Maple - edge chipped.jpg

And the edges I just cut today with the new Shelix cutterhead -
011 - Curly Maple - edges clear after Shelix cutterhead on jointer.jpg

David
 

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since Barnum & Bailey has closed, there are two gorillas looking for work.
maybe they can haul that thing around for you when you start putting it together.

.
 
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Hi David. Found the "Project Showcase" you mentioned. That's quite the project your working on. Beautiful wood. Hope you have some strong help to get moved. Anxious to see your cutter in action.
 
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David
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Discussion Starter #13
I may make a video of the entire build once this is complete, not sure, video production takes a while. :wink:

Finally got to a point where I could begin joining the boards for the shelves and started with the Hard Rock Maple. I'll save the much more expensive Curly Maple for the last in case I learn something new when I join these boards.

Because these are heavy and the edges so crisp they're sharp I decided to do one joint at a time rather than attempt gluing all three boards at once. That turned out to be a good move because doing just one joint is about all the open time I have for TB I, probably could have switched to TB III to get more open time but didn't want to do that.

I used biscuits for making certain everything stays aligned, not for strength, and it worked well for this application.

013 - Cutting biscuit slots.jpg

014 - Biscuit slots.jpg

015 - Started gluing shelves.jpg

016 - One shelf glued.jpg

David
 

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David
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Discussion Starter #14
Loaded the three shelves, two Hard Rock Maple and one Curly Maple, and headed 10 minutes away to my friend’s cabinet shop. They have a 24” spiral head planer and 36” wide belt sander.

It still took an hour to plane and sand these heavy boards but it would have taken days per board in my shop.

018 - Shelves loaded to take for planing and sanding.JPG


019 - Curly Maple shelf being planed.JPG


420188


David
 
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