Originally Posted by dgage
Looking good Ambesolman.
One thing that I did when building Coach's box recently is build in overlaps and then flush trim with a router. Besides cutting the exterior pieces oversize, I also set the order of assembly to make it so I would have an edge to flush against. An example was the sides, I inset them and then the front, back, top, and bottom edges overlapped so I flushed each of those edges at the same time with the router bit bearing riding against the side of the box. I also put the top on so it overlapped front (inner) and back, etc. Resulted in a box that almost looked perfect without having to worry about cutting perfect pieces, which even with my copious amounts of woodworking tools doesn't always happen (OK, rarely).
By the way, I know you have mentioned using some other wood outside, make sure you stick with plywood. If you were to use real wood, it is a living thing with cells that will take in and let go of moisture based on humidity. If you build it on a box without taking into account that real wood moves, you'll have cracks or other issues. You could put in wood strips on the edge if you wanted to round over wood and then put on veneer, but don't put a layer of real wood on a side without taking into account wood movement...or making sure it is very thin, like 1/8" or so.
One other option for the top that is fairly inexpensive and could be customized to fit is concrete countertops. I remodeled my kitchen and have a large L shaped island and didn't want a seam. So I did an in-place pour of concrete and it looks phenomenal. It doesn't look like concrete, more like granite as I used some stones, colored glass, and even some glow stones. I could walk you through it if you were interested in giving it a shot.
I'm really looking forward to your build and excited you are finally moving forward with this project. Now hurry up already!
Welcome to the party David, appreciate the input as well!
So I'm planning on basically having everything else sandwiched btw the outer baffles. However, since those walls will be firing into the couch and chair, maybe I should dbl the side walls and have everything sandwiched btw them so it'd look better when being looked at head on (looking at the short end of the granite)?
I probably wasn't clear about using another wood on the outside...I'd be using plywood outside + mdf inside OR just plywood (Baltic birtch, etc) for the whole thing. I still have to play with the cutsheet program. I think there's even a 4x10' option for BB and even a veneered mdf
I feel like as long as I take my time, taking multiple measurements before cutting, it may be easier for me and my limited experience to cut them right the first time. Otherwise I'd have to have a fixed amount of extra to try and remember to add in, then build off of, then cut off. I'm more likely to mess up with more variables/more to do. I may do this with just the outer pieces, but maybe that's what you're saying?
Your countertops came out great! If I hadn't gotten a free slab of granite and already gotten it cut, I'd definitely consider going the concrete route. You can make it look however you want it to which is awesome. As it is now, I'll have a matching piece of granite if/when I build a second box. So they should look identical, at least in theory
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