I've had this idea for some table lamps for quite awhile now. Since I built those other two - with the maple arches and walnut doughnuts - not sure we need more table lamps. But I have to see if I can do this. So here goes:
Step 1: Draw up a design and get some wood. I had some beauty curly maple thins from Mike1950 and got some nice mahogany from Larry. Got a couple more maple thins from Mike so I now have wood. Checked the design against the wood to ensure the dimensions were compatible with the wood. In short, the design provides for a mahogany frame box with side panels made from the maple thins. Polished agate slices will be inserted into the panels. An LED light will be inside the box. The main light socket will extend out the top of the box. A single two pole switch will turn on the light inside the box, the main light, or both. The base will be mahogany. That's the plan.
Step 2: Figure out how to insert the agate slices into the panels. Decided the best option was to decide which side of the maple thin would be the outside. Placing the maple thin with the inside surface up, center an agate slice and trace around the agate slice. Then duplicate that line approximately an eighth inch inside the first tracing. Drill several starter / change of direction holes; put a fine tooth scroll blade in my jigsaw and cut out along the inside line. Use wood files to smooth out any rough spots and get as close to the line as possible. Note: The edges of the agate slices aren't square, they taper on way or the other. You want the largest side down against the panel when you trace it. That's also the direction the agate will be inserted during final build. If you put the agate slice in so the edges taper away from the hole, there's a good chance light will shine around the edge of the agate.
Step 3: Get a new toy - justify it to wife because she'll get two new table lamps. My new toy is a trim router. Went with the DeWalt variable speed, it seemed to get the best reviews all around and wasn't the highest priced one. It just seemed way safer than trying to use my big router. Put a rabbiting bit with a bearing in the router and set the depth to approx half the thickness of the maple thin. Then route around the inside of the cutout. This produces approx a 3/32" rabbit all around the inside of the cutout.
Step 4: Test fit the agate slice. If it doesn't fit, determine where a little trimming is needed and mark those areas with a pencil. Insert a flat trim bit in the router, set the depth the same as the rabbit, and then carefully widen the rabbit where needed. Test and repeat as needed until the agate slips into the rabbit with no force (you don't want to crack the agate slice).
When done, the agate slices should fit snugly into the rabbit. Looking at the panel from the outside face, I didn't want to see any light coming through around the edges and I don't. So far so good. I'll sand and probably round the outside edge of the cutout. I think it would look very cool if I could put a shallow angle taper around the cutout but not sure how I'd do that.
Made four panels today. Next, make four more panels, cut out and rough sand the panels (so I know the final thickness) and then start the mahogany frame.
Step 1: Draw up a design and get some wood. I had some beauty curly maple thins from Mike1950 and got some nice mahogany from Larry. Got a couple more maple thins from Mike so I now have wood. Checked the design against the wood to ensure the dimensions were compatible with the wood. In short, the design provides for a mahogany frame box with side panels made from the maple thins. Polished agate slices will be inserted into the panels. An LED light will be inside the box. The main light socket will extend out the top of the box. A single two pole switch will turn on the light inside the box, the main light, or both. The base will be mahogany. That's the plan.
Step 2: Figure out how to insert the agate slices into the panels. Decided the best option was to decide which side of the maple thin would be the outside. Placing the maple thin with the inside surface up, center an agate slice and trace around the agate slice. Then duplicate that line approximately an eighth inch inside the first tracing. Drill several starter / change of direction holes; put a fine tooth scroll blade in my jigsaw and cut out along the inside line. Use wood files to smooth out any rough spots and get as close to the line as possible. Note: The edges of the agate slices aren't square, they taper on way or the other. You want the largest side down against the panel when you trace it. That's also the direction the agate will be inserted during final build. If you put the agate slice in so the edges taper away from the hole, there's a good chance light will shine around the edge of the agate.
Step 3: Get a new toy - justify it to wife because she'll get two new table lamps. My new toy is a trim router. Went with the DeWalt variable speed, it seemed to get the best reviews all around and wasn't the highest priced one. It just seemed way safer than trying to use my big router. Put a rabbiting bit with a bearing in the router and set the depth to approx half the thickness of the maple thin. Then route around the inside of the cutout. This produces approx a 3/32" rabbit all around the inside of the cutout.
Step 4: Test fit the agate slice. If it doesn't fit, determine where a little trimming is needed and mark those areas with a pencil. Insert a flat trim bit in the router, set the depth the same as the rabbit, and then carefully widen the rabbit where needed. Test and repeat as needed until the agate slips into the rabbit with no force (you don't want to crack the agate slice).
When done, the agate slices should fit snugly into the rabbit. Looking at the panel from the outside face, I didn't want to see any light coming through around the edges and I don't. So far so good. I'll sand and probably round the outside edge of the cutout. I think it would look very cool if I could put a shallow angle taper around the cutout but not sure how I'd do that.
Made four panels today. Next, make four more panels, cut out and rough sand the panels (so I know the final thickness) and then start the mahogany frame.
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