This curved front display case was built and designed by JKM Woodworking, and it’s perfect for showcasing collectibles. In this guide, we’ll walk you through the steps to create a stunning display case that features a curved front, making it a great addition to any home.
Materials and Tools Needed
- Cherry wood
- MDF (Medium-Density Fiberboard)
- Cherry veneer
- Plexiglass
- Epoxy wood glue
- Wood dye
- Shellac
- Lacquer
- Router
- Bandsaw
- Table saw
- Miter saw
- Thickness planer
- Circle cutting jig
- Clamps
- Sandpaper
- Steel wool
Step 1: Cut the Top and Bottom Panels
Start by cutting the top and bottom panels to an exact length of 18 inches and a width of about a quarter inch wider than the tip of the radius of the curve. These panels will have an MDF core to prevent warping and wood movement over time, and they will be covered with an eighth-inch thick cherry veneer that you can make yourself.
Step 2: Create the Circular Arc
To cut the circular arc on one side of these panels, use a circle cutting jig. Attach a pivot cookie at the center point of the workpiece and set the jig to an 11 and a quarter inch radius. This jig works in a two-step process: first, make a rough cut on the bandsaw, then use the router table with a quarter-inch straight bit to clean up the edge and achieve the exact radius.
Step 3: Cut the Facer Boards
Next, rip the facer boards to width on the table saw and cut them to rough length on the miter saw. Plan the cuts to ensure continuous grain along the front and sides of the display case. These longer centerpieces will form the curved section across the front, created using a bent lamination process.
Step 4: Bent Lamination Process
For the curved front facer boards, resew a piece of wood into thin strips on the bandsaw. Clean up the surface with a sled on the thickness planer, then glue the strips back together using a circular arc form. The clamping form is made using the same circle cutting jig.
Step 5: Cut the Miter Joints
Determine the angles for the front corners. After some calculations, set your miter saw to 18 and a half degrees to cut the side pieces. For the curved front pieces, use the form from the bent lamination glue-up and cut at 18 and a half degrees using a cross-cut sled.
Step 6: Glue Up the Frame
With all the miters cut, it’s time to glue the pieces together. Use painters tape to hold the miter joints in place. Apply glue on the end grain, let it soak for about five minutes, and then pull everything together with a strap clamp. Repeat this for both the top and bottom pieces.
Step 7: Sanding the Joints
After the glue dries, sand the joints to achieve a smooth finish. The eighth-inch veneer helps prevent sanding through the panels. Check the joints to ensure they are tight and the continuous grain looks great around the corners.
Step 8: Create the Pillars
Next, create the four pillars. The back pillars will be simple squares, while the front pillars will take on a pentagon shape. Make necessary cuts for the grooves that will hold the Plexiglass and for the mortises for the cross members.
Step 9: Cut the Cross Members
Cut strips of wood for the cross members, which will span between the pillars. Use a crosscut sled to cut the pieces to length and to create tenons on both ends.
Step 10: Finishing the Pieces
Before assembling, apply a combination of two colors of dye mixed with shellac and denatured alcohol to the pieces. This step is essential for ensuring an even finish on all surfaces, especially in the intricate corners and angles.
Step 11: Final Assembly
Once the finish is dry, glue all the pieces together using epoxy designed for wood. Use helper blocks to keep everything straight and square during the assembly.
Step 12: Install the Acrylic Panels
The last step is to cut down the cast acrylic panels to size and install them in the grooves of the pillars. Remove the protective coating and slide the acrylic into place. Ensure that everything fits perfectly.
And there you have it! A beautifully crafted curved cherry display case, perfect for showcasing your favorite collectibles.