A couple of the older boys helped rip up two blocks of fir (called pino cipress here) into 4 cm thick slabs during September so that it could dry by the time I returned from my trip. Unfortunately, I don't have any pictures of this process.
After my return, we planed the slabs down to 3 cm thickness and trimmed them up to make them into finished lumber. After that, we formed the tongue and groove pattern on the edges using multiple passes with a rabbit bit and then a slot cutter on our provisional router table.
|The shop-made tongue and groove pine lumber.|
|The shelves now glued and clamped together.|
|Andres Castro using the belt sander while Arley Rocha observes.|
|Camilo Castro trying his hand with the Dewalt belt sander, which can be a challenge to control, especially on the far side of the shelf.|
|Arley Rocha taking his turn sanding.|
|Preparing to hang the shelves for painting|
Finally, it was time to begin applying finish. We applied three coats of sanding sealer and then two coats of tinted lacquer to make a nice, smooth finish. Of course, we sanded the surfaces again lightly between coats.
|William Gomez applying sanding sealer to the shelves.|
|The shelves before the tinted lacquer was applied.|
We completed the shelves on November 3rd, a few days later than promised, but they turned out very nice.
|The completed shelves as installed at the IMC office|
Nancy Centeno, the IMC Director in Colombia, liked the shelves so much that she has asked us to make three more for her office...