I’m making a prototype of a case I’ve designed to hold 6 Omega watches. There are a few ways I could go about making this, but I’ve decided to make it out of MDF and then veneer over all the surfaces. This is so I can use a burr veneer, which would be very expensive to make from a solid block.
The first step was to draw a template on a piece of 18mm thick MDF. The curves at the corners have a radius of 35mm, and the curves that join them up at a tangent have a radius of 615mm. Here you can see that I’ve cut the corner curves with a large ‘forstner’ drill bit.
I cut the other curves using a router attached to a trammel. After a bit of tidying the curves up with a sanding bobbin, I cut out a rough shape of the next layer with a jigsaw. I glued the two layers together by clamping them in the vacuum bag press. The bag press is great for giving a strong, even pressure across a large surface area.
The cutter is exactly the same diameter as the bearing guide on the end, so the cut of the second layer will follow the guide which is set to the first layer.
After glueing up a few more layers, each using the previous layer as a template, I cut the outside curves on the bandsaw. The next step is to attach the veneer…