Custom One-Off Audio Shelves

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Randall Kepley

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Custom One-Off Audio Shelves
« on: 13 Jan 2012, 04:49 am »
Hey Guys, Ive never posted anything in this section of Audio Circle before but theres a first time for everything. I thought you guys might like to see some One-Off shelves Im building for a customer of mine. This is the first of many projects he and I have in the works so lots more will be posted in the future, but anyway .... The first in the "Projects" is replacement Component shelves. The shelves are 18" Deep X 25" wide X 2" thick HDF (high density fiberboard) most of you are familiar w/ MDF. This stuff is a lot more dense and stiffer not to mention heavier. I started off by Vacuum pressing 2 - 1" pieces together, did I mention this stuff is Heavy???






And heres what you have after a lot of cutting and Vacuum pressing. The wholes are 2" off each corner to the center and are an 1 7/8" OD with an ID of 1 1/2".Each hole will have a nylon bushing installed to to protect the Veneer from the threaded rod from chipping the veneer when installed.

The Veneer my client chose is "Angel Step Burl" Maple. Very beautiful and highly figured.







Here you can see the first edge after it has been veneered, you can do it either way but I like doing the edges then the flats.






Hope you enjoyed , Randall Kepley

Vapor Audio

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Re: Custom One-Off Audio Shelves
« Reply #1 on: 14 Jan 2012, 12:01 am »
Looking forward to seeing finished pics, since I've been eyeballing some of that same Angelstep Maple Burl from wood-veneers ... and because I need to build a nice rack myself.

audiogoober

Re: Custom One-Off Audio Shelves
« Reply #2 on: 14 Jan 2012, 02:56 am »
Hi Randall,

Gorgeous pics!

« Last Edit: 14 Jan 2012, 05:10 pm by audiogoober »

Randall Kepley

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Re: Custom One-Off Audio Shelves
« Reply #3 on: 14 Jan 2012, 05:48 pm »
Update, After all the edge banding is done and flush cut its time for the Vacuum press. Now ill tell you if you can ever find yourself in the position to buy one , buy one. It will evermore change the way you do veneer work. To do it and do it right you will have between $ 800 - $ 1000 invested but its worth every penny if you do much of it. The first 3 pix show the veneer being pressed @ 20" of mercury.









The next few pix is 45 min later, the cold press glue is Rock hard, the shelves have been removed and the edges can now be flushed trimmed.






For those who may be wondering , the bit im using isnt your typical flush trim bit. A flush trim bit will work pretty good on most veneers but when it comes to Burls or any figured wood there is a good chance of tearout. This bit is a "Downward spiral" not an "Up spiral" w/ a bottom bearing. What this does, is as the bit cuts its cutting in a downward sheering motion which the veneer is supported by the substrate. An up spiral tend to want to try to "Lift" the unsupported veneer resulting in chipping or tearout.

The next 2 pix shows where the center of the hole has been located and punched through.






Next the router has been inserted w/ the same bit and the hole can be cut. In the last pix you can see the nylon bushing fits like a glove , ready for glueing in place once the shelf has been finished.






This last pix in this portion shows a common problem in working w/ burl. In all my yrs working w/ veneer I have yet to get in burls that I didnt have to deal w/ a hole somewhere in the burl. In the next few days Ill show you how I deal with this to achive a perfect match which will make this invisible.



To be continued..... R.K.

Vapor Audio

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Re: Custom One-Off Audio Shelves
« Reply #4 on: 28 Jan 2012, 05:57 pm »
Be careful with those 1/4" spiral flush trim bits.  The 'bearings' are just shims essentially with no ball bearings in them, so they heat up quite a bit when in use ... and have a tendency to fall off at just the wrong moment.  Which when that happens, your bit eats about 1/2" into the side of your work surface.  I've had that happen to me enough with those kind of bits that I don't use them anymore. 

Any new pics of the veneer with a finish applied?

Bob in St. Louis

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Re: Custom One-Off Audio Shelves
« Reply #5 on: 28 Jan 2012, 11:20 pm »
To do it and do it right you will have between $ 800 - $ 1000 invested but its worth every penny if you do much of it.
Very good looking rack Randall, looking good.  :thumb:

I was wondering the same thing about those bits. Never seen such a thing, but they worry me too. Have you tried using a "good ol fashion" bearing type?

Also, for the price you mentioned, can you give a model/spec/link to the type of equipment you're using please?

Thanks for the pictures!
Bob

Rclark

Re: Custom One-Off Audio Shelves
« Reply #6 on: 28 Jan 2012, 11:29 pm »
that would be the ultimate gig, hand crafting beautiful speakers.  :thumb:

Vapor Audio

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Re: Custom One-Off Audio Shelves
« Reply #7 on: 28 Jan 2012, 11:55 pm »
that would be the ultimate gig, hand crafting beautiful speakers.  :thumb:

You would think so  :?

Randall Kepley

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Re: Custom One-Off Audio Shelves
« Reply #8 on: 30 Jan 2012, 04:18 am »
Be careful with those 1/4" spiral flush trim bits.  The 'bearings' are just shims essentially with no ball bearings in them, so they heat up quite a bit when in use ... and have a tendency to fall off at just the wrong moment.  Which when that happens, your bit eats about 1/2" into the side of your work surface.  I've had that happen to me enough with those kind of bits that I don't use them anymore. 

Any new pics of the veneer with a finish applied?

Never had a problem w/ the bits flying apart (bearings) that being said this is the only application I use this type of bit for. Its down ward cutting bit and I only use these for veneer I may use this a max of 20 seconds at a time. They work a lot better than a regular flush trim bit that is cutting parallel to the edge. Ill be spraying the final finish on them tomorrow, they look fantastic! R.K.