Oboe Swell Complete

I finished modifying the swell shade frame and moved on the box itself.  I built the support frame using pocket screw joinery.  This was my first endeavour using this joinery, and I love it!  Joints are clean and sturdy.  Completed frame is pictured.  (Click on "From Swell Box" in blue letters below to see more pictures.)  I then mounted the shutters in place.  I made the side panels out of 3/4" plywood.  All the visible panels are oak, the top and rear are premium pine.  The lower front panel and the back panel are wider than the 4' wide plywood, and wanted the grain to run vertically.  I used the pocket screws and pipe clamps to glue up two pieces of plywood side by side to make these panels.  I used threaded wood inserts and a bolt through the frame to hold the panels in place.

From Swell Box

Next, was applying oak veneer to almost everything.  The shutters and their frame work were originally painted flat black.  Because the swell will be prominently visible, I want it all to be oak, matching the console and other case work.  I removed the individual shutters and sanded all surfaces.  The shutters' framework needed to be planed and sanded to ensure a smooth, even surface for the veneer.  Most of the veneer came in paper backed 4x8 sheets.  I cut them very carefully so there wouldn't be any seams in the grain showing.  I used two-part epoxy for the adhesive.  I had to work very quickly, as this product gave 3-5 minutes of open working time.  I don't have any pics of applying the epoxy because I had to work so fast.  I will say, an old credit card makes an excellent application tool- makes a smooth, uniform layer of epoxy.  The veneer was clamped in place and allowed to cure for 24 hours (pictured above).  That cure time really drug the process out, but I wanted to be sure I had a good strong bond.  When the broad sides were done, I was able to apply the iron-on edge veneers.

I decided to paint the interior with a black, oil-based enamel paint.  I am hoping that the hard paint will help reflect sound out more than bare wood.  Plus, it looks more finished as well.  Next, I added some simple crown moulding to the top to dress it up just a bit.  None of the woodwork in this whole project is ornate or frilly, but it really needed something up there.  Then I counter sank a nylon washer at the bottom of each shutter to reduce the friction of the rotating shutters. 

Finished swell box is pictured here.  All that remains to be done is filling in a few nail holes with wood putty, and of course staining the exterior.  However, I think staining will wait until I am ready to refinish the console and one other decorative panel.  And, the mechanical linkage to the swell shoe is under construction, but I will give that its own post later.