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. 😉
Preliminary design -
One shelf, basically, prior to jointing -
All the lumber for the project -
Curly Maple close up shots -
More photos and updates as I work through this project. Enjoy!
David
That's actually one of the websites he showed me for a sample, Rick. But nobody wanted to make one as large as this, at least not for a price that makes sense. It's also not that easy to find 8/4 Curly Maple longer than 48", either. I bought this from Kevin at Curly Maple Wood which is where I've bought all my Curly Maple forever, it seems.
It will be tricky avoiding it look clunky with those dimensions. Softening the corners may help but I would do a sample with cheap construction lumber to play with and have approved.
Rob
Every edge will be rounded or chamfered to some degree, Rob. Build a test piece out of construction lumber ain't happening, though! Two entirely different materials and unless someone wants the test piece afterward it would be a total waste of time and funds. Besides, I'm allergic to Pine so that's rarely ever in my shop.
He showed me a photo and said, "I want one like this but bigger." That's all the approval I need.
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.
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!!
I’d love to change the head in my jointer and Planer to those heads also , but there ridiculously priced .
I had no idea conventional heads were that bad in this application.
I’d love to change the head in my jointer and Planer to those heads also l but ridiculously priced .
I had no idea conventional heads were that bad in this application.
If I hadn't moved the boards into a different room or looked at them closely I would've thought they were good (they're in the house for now :grin. The areas I looked at were good but I didn't look at all edges.
About $400 for the head, bearings, 10 extra cutters, and shipping. I'm sure it's going to be worth it but I'm also very reluctant to spend money. :wink:
I got an email about the order this afternoon and they're back ordered - ugh! They said it could be 3-4 weeks. So I guess I'll work on something else for a while... :frown:
Unfortunately, yes, I paid for it yesterday. It never occurred to me to check with Grizzly or that this cutterhead fit other machines. Oh, well, live and learn I guess.
+1 Echo: Great looking wood! And a wonderful project for showcasing it and your skills.
FYI & FWIW - I was doing some searches for wood identification not too long ago, and came across this excellent resource for discussions about wood species identification, which also offers peer to peer wood sales https://woodbarter.com/, noting that I have no experience actually buying wood from anybody on that forum, just that most of the wood that I seen there is quite beautiful. Prices? Sorry, I don't have any sense of them being high, reasonable, or otherwise.
In similar audio equipment work, my son has asked me to build something similar to this, BUT, with the electric adjustable desk legs I recently assembled for him, I thought he only wanted a desk top, he said that this is a desk top !!!
This set up is by Prime Cables and the same thing is offered by V Ryzer. Please beware that there are 2 corner models available, the one we have is a ''V'' and there is also an ''L'' I saw on the web site. I wish my son would have gotten the ''L'' shape it would be easier to work with a 90 degree angle rather than whatever we have. Trying to fit the top he wants is a head scratcher for sure. The 3 leg models are quite capable and can lift 340 lbs. The desk( picture I posted) is over $3000 to buy and only made from melamine ! Because of the span between the legs I want to use 1'' thick MDF or hardwood. The span on the "V'' shape legs from side to side is 88'' if I use 3/4'' I'm sure it will sag. The desk will be for his recording studio and will hold several electronic devices and there is a pull out slider in the design for a pretty big keyboard, my son's Yamaha keyboard is so big ! it weighs 70 lbs and is 54'' long, but that is just one of them !
Given your previous experience, do you think the 1'' MDF is strong enough to not sag, I am referring to the desk top only. The upper shelf and the body will all be 3/4'' MDF and everything will be covered in a wood grain style of laminate, probably Wenge or Walnut colors. TIA.
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! 😁
Here are the chipped edges -
And the edges I just cut today with the new Shelix cutterhead -
I may make a video of the entire build once this is complete, not sure, video production takes a while. 😉
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.
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.
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.
I haven't done much with my son's desk top but I did cut and install 1 '' thick MDF and it is not sagging. I will post more when something worth posting. For now we decided to just keep it geometrically simple, a rectangle 45'' x 97'', man is that stuff heavy !!!
It has been ages since I've posted about this project but it is now finished and delivered. There were many delays due to other contracts and jobs with hard deadlines so this got set aside many times (this one had no deadline). Even though it is completed and delivered I'll still post the steps to build and finished photos at the customer's house. And you're not going to believe how high-end his audio system is - amazing!
Laying out the Purpleheart legs for cutting on the CNC. I don't have a flat bottom blade for the table saw and since I have the CNC it just made sense to use that to ensure all the cuts were uniform.
Here are the toolpath profiles for the cuts I made on the CNC -
And the setup on the CNC to prevent blowout when the bit cut through -
Here are the five legs after cutting on the CNC and beveling the top and bottom surfaces on the table saw -
More in a bit -
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