Tuesday was spent prepping the top panel. I used some paper-backed veneer that isn't really fit for view as the backer for the MDF substrate. After making sure I had a good fit between the MDF and mahogany frame, I applied Titebond II to the MDF, laid on the veneer, taped it in place and put the assembly in the vacuum press. While that was in the press, I sanded the outside of the radius front of the frame to final dimension. Next, I finished prepping the veneers for the top of the panel by taping them together.
Then, I applied Titebond II to the substrate:
Aligned the veneer to the substrate:
After taping the edges of the veneer to the substrate, I placed the assembly in my vacuum press:
While the panel was in the press, I did a little more sanding on the frame radius and made sure all parts were smooth. Then, I started routing the profile on the front and sides. (Note: the table edge router bit is larger than the opening in the factory router base, so I had to make a custom base with 1/4" birch ply). I cut the profile in five passes to reduce the chance of tear-out. When I was satisfied with the results, I made another final pass with the bit no more than another millimeter deeper for a final clean-up.
Here's what I have so far:
..and a closer look:
LOML arrived home from work about 5:30 and had to take a look, of course. The panel still needed to stay in the press about another hour, but she was pleased with the frame. About 6:30, we came back to the shop and she helped me take the top panel out of the press. So far, so good!
I had several errands to run this morning (Wednesday), so I'll only have about four hours of shop time today, which is still better than none!