The concave shell and the large recess that is in the door makes it a lot of work to remove all that material.
I took a portion of the plans and cut out the shell and door pattern.
I milled a piece of mahogany 1 inch thick and fitted it to the opening. Then I traced the pattern on to the door with carbon paper.
The bottom pattern shows how much material that I have to remove to make th recess.
I carved a practise shell in a scrap piece of mahogany. A little practise never hurt anyone.
The first thing I needed to do was remove a large portion of the recess with my dado set mounted in my radial arm saw. I moved it over 3/4 inch each pass.
I picked this piece of mahogany because of the straight grain, only to find out that the grain changes direction right in the middle. Oh well have to carve in a different direction
I have the recess carved out now and lightly sanded. Now I have to carve a dish at the top for the shell.
Carving the dish 1/4 inch deep for the shell.
Now that the dish is created, I copied the shell pattern on using carbon paper. I marked out which of the shell rays are to be lower and which would be upper.
I carved the shell rays by lowering the two from each side of a raised one and then rounding it over.
Here I am carving the lower one next to the raised ray.
After carving the shell, I cleaned up the tool marks using a little ultra flexible sand paper from 3M. This is the first time that I have used it and I think it is great.
All cleaned up ready for the lock.
I marked out where I wanted it positioned and then traced around it for the pattern.
Then using a chisel and hand router plane I created the lock mortise
I used a jig saw to cut out the material in the shape of a key hole.
I temporally mounted the escutcheon and made sure the lock was working smoothly.
I mounted the hinges on the door in mortises created with the router plane. The hinges are 2 inch brass.
Putting the hinge mortises in the kneehole with the router plane was a real pain because of the narrow opening. I cut a mortise for the lock in the left side of the knee hole with a short chisel. The kneehole is only 10 inches wide. There is not a lot of room to work.
The door closes and locks correctly, so that step is complete..
Now I think I'll go back to working on the drawers.
Here is today's video: