Big assembly

[Crazyraceguy]

Finally getting around to assembling a job I started over a month ago. The parts were cut, sanded, and sent to the finish department.....when the screw-up happened. Apparently, the drawing made it to the shop without the final update. Dimensionally, nothing changed, so the parts were the correct sizes. The change was to the finish. 30 of the 48 vertical members already had been clear lacquered, before anyone realized it. They were supposed to get a very dark stain first. This meant a lot of stripping and sanding. Being veneered parts, this was a huge hassle. The finish guy and his helper spent a lot of time and effort to get this corrected.
This is the ultimate use-case for the DF500. I don't see any other way to do this at even close to the speed this can be done with the Domino. Sure a router/jig, dowels, even a panto-router could do it, but the set-up would take a lot more time.
The dowel method would be a real pain, because of the off-set. The vertical members are 1/4" narrower than the border parts.
All it took for the DF500 was a couple of off-cuts(with Dominos in them) and some spacers, leapfrogging each other after the cut.
There a three sections of this, two of them joining in the field. One is 96" wide, with the pair at 78" each.
The groove in the bottom is there to cleat it to the floor and the vertical posts penetrate a drop ceiling, attaching above it.

 

[jonnyrocket]

A very cool detail, but an even cooler build! 

Was the veneered lumber ordered in the dimensions seen here?

 

[Crazyraceguy]

No, this was a special individually layed up situation. The core of the vertical parts is 1" particleboard, cut to 5" width initially. The thicker parts are 2" thick, a glue-up of 2 layers of 3/4" sandwiching a piece of 1/2", also 5" wide. This was done so that it could be veneered with strips, rather than a full sheet. There are no seam lines, from the leaves of veneer, in the faces of the boards. This really adds to the illusion that they are solid wood, though it was much more noticeable before that dark stain.
Then those 5" pieces were cut down. The frame pieces are 4" wide and the inner slats are 3 3/4", all edged with the same veneer.
Doing it as whole sheets would have been more efficient, at least for the 1" material. I can't even imagine wrestling with that 2" as a whole 10' sheet. That decision was made long before it ever got to me. The 5" pieces were done by a veneer specialist. I did all of the width cuts and edge veneering after that, plus the length cuts and joinery.
I really wanted to send these as pieces, to be assembled on-site, but got overridden. They are super heavy and not the most stable thing ever. There is nothing to keep them square until installation. At that point, they will be rock solid, but they have to get there first.....  [unsure] fingers crossed.

 

[olchunkofcoal]

Really nice build and use of the scraps to layout and mortise in one go.

How is the bottom plate fastened to the cleat? A few discreet screws and/or a good helping of construction adhesive?

 

[Crazyraceguy]

Really nice build and use of the scraps to layout and mortise in one go.

How is the bottom plate fastened to the cleat? A few discreet screws and/or a good helping of construction adhesive?

Probably a little of both. The vertical members will be attached to the top/bottom plates with Lamello Clamex connectors. That is also what is holding the plywood "shipping" plates on there in the pics. So there will be a 5mm hole at each connection, and likely a cap to cover them, another screw or two won't stand out.