Case for a 'duelling pair'

[labr@]

Just a bit of a story about my pallet challenge entry. The theme I worked to was “Case for a duelling pair” – the duelling pair being my 2 japanese pull saws.

The top and bottom panels were made from layers to help reduce warping. Also this was a good way to make a panel large enough that would not be prone to splitting. Strips were cut and laid down in 2 layers with the grains running at right angles. The face veneer was then laid onto this. The banding was done by putting pieces with end grain face up between 2 strips. This was the only way to obtain some significant colour contrast from an all pine pallet.

Corners are mitred with 6mm splines (because I have a 6mm router bit).

The saw mounts are a ring for the handle and a flat support for the blade, with a rim to stop it slipping sideways and 2 rare earth magnets underneath. It works nicely by slipping the handle into the ring and then placing the blade onto the support. Removal is the opposite of course.

Filling of nail holes was with a mix of white glue and sanding dust collected during the project. Finish is simply tung oil. It will receive a few more coats over time. Finished size is 650 x 180 x 42 mm.

I originally had grand ideas of concealed hinges, a carry handle and latches but it is really just a storage box for the shed to keep the saw blades protected so in the end a couple of pieces were glued inside at the ends to align the lid. The fit turned out quite well and the lid stays in place with a nice friction fit.

The idea of these challenges is to try something different and this one made me do that as I had not done splines, veneering or inserting panels in frames before. Tried mitred corners on one project about 20 odd years ago but this time was like a first go too.

Glueing up the panel from strips
1 Glueing up the panel [800x600].JPG


The veneers and banding strips were rougher than I thought but it sanded out OK.
3 Rough veneer [800x600].JPG2 Gluing on veneer [800x600].JPG

Ready to glue it all together
4 Ready to glue panel in [800x600].JPG

Rigged up a box clamp system using corner pieces cut from the pallet in conjunction with F clamps and kayak tie downs.
5 DIY box clamp [800x600].JPG

Glued up and ready to cut open
6 Before cutting [800x600].JPG

After cutting
7 After cutting [800x600].JPG

Magnets in pockets about to be covered by the piece bottom left.
8 Magnets [800x600].JPG

Saws in place

9 Saws in place [800x600].JPG

[coffenup]

nice job mate
regards Michael