Knife Display Case - WIP

[Brokenolmarine]

Over the last few days I have made some decent progress.  I started on the case top.  I was going to use the smaller of the two boards I prepped, but I was NOT happy with the look, and the fit was TOO close and might have been way too short after trimming.  I went back into the woodpile and found some black cherry I liked and went thru the process.  I ripped two long pieces the right width, then cut the four pieces needed to make the frame and test fitted them together.

The test fit was successful, and I needed to sand away the burn marks caused by the table saw.  This was caused by the density of the wood and the length of the cut.  Note that the dados on these are not as wide and are very shallow.  Rather than setting up the stacked dado blade, I cut these in two passes over the table saw blade.  The sanding of the top frame was accomplished on the new 1x30 belt sander with the platten.

[Brokenolmarine]

Got the case top glued up and pinned, and let the glue cured using all the same processes as the previous ones used on the case.  Cut the plugs using the 1/4" plug cutting from the special tools drawer.

This time I cut plugs from the leftover scraps of Black Cherry... and I cut a bunch even though I only needed four.  I planned to snap them loose rather than setting up the bandsaw to cut the bottom off the scrap, so there was a chance some wouldn't break clean at the bottom.... extras are nice to have.

Got them all plugged and left them to cure.

[Brokenolmarine]

After trimming the plugs flush with the mallet and chisel, I test fitted the top frame to the case.  It's looking good.  I won't apply any finish until the top's edges have been shaped and I have prepped everything for final assembly.  Next step is to cut the plexi.  A REAL pucker factor moment.  Crack that panel and it's $50 to replace the panel... 

 

We are getting close, but I have been slowed down a bit.  CUT the tip of my right index finger last night cleaning a broiling pan, cut it deep.  I know now why torturers start on the fingertips. 

[Brokenolmarine]

Went to Home Depot this morning and picked up a couple things.  I picked up four more hanging loops, this thing is getting heavy.  I also picked up a package of special blades for the jigsaw, made especially for cutting plexiglass, after watching a couple videos on "How best to cut Plexiglass without breaking it."  Who Knew they had special blades?  The teeth on the blades are smaller, closer together, and angle BOTH ways, opening a channel rather than melting back together behind the cut, leaving a smooth clean cut.  

NOT cheap, but after cutting this panel, worth every penny.  It fits, and the cuts didn't need to be sanded or cleaned up in any way.  

 

For now, I have left the protective sheeting on the panel.  It will come off later, when everything is done and I'm ready to fully assembly the case.  Still have to drill some Tiny Holes to mount the plexi, mount the hinges and latches, mount the lights and the hangers.  Almost done here.

Done, for the day.  

[AlZilla]

Got it. I was picturing this thing laying flat on a table. Now I see where you're going.

 Also - special blades for plexi ... ?!  Cool. I might revisit making plexiglass patterns.

[Brokenolmarine]

It's going to hang over the table by the front door in the entry, and will be lighted to show off the knives.  Vertical display, that's the reason for the long magnetic double bars.  I'll try and get a pic of the location in the morning.  We are getting close to the end now.  I need to shape the edges of the top, and stain it, then add the LONG piano hinge and the latch to hold the door closed.  This will have SIX hangers.  SIX.  That should hold 'er.  

[Thadrick]

I use a flush cut bit in my router with a strait piece of wood as a guide for cutting plex. I also use it for cutting thin aluminum panels very successfully 

[Brokenolmarine]

As promised, here is the pic of the address where the case will live.  The painting and the lamp will go away, and the medal / flag display will likely be moved to another location.  I made that from a chunk of firewood we were splitting from a tree we cut down.  The boxes on the table will stay, they contain the sheaths for most of the knives. 

 

I'm thinking seriously of hanging my Marine NCO Sword above the display case, and maybe my Calvary Sabre Replica below it.  

[dikman]

Hanging the swords next to the case is a good idea as being edged blades they fit the theme. How about crossed swords above the case? just a thought.

[Brokenolmarine]

I was thinking the sword and the scabbard crossed above the display case... Then a gift from a friend in return for what they considered a huge favor... A high end collectible  replica of the Braveheart sword hung vertically to the left of the table.  The thing is Long... Four or five feet, weighs about ten pounds.