Modern-Style Pulpit
This has been my most intimidating project to date, since it's going to be seen by a bunch of people on a regular basis, and was for someone with a pretty demanding eye. I'm more or less pleased with how it came out, though there were certainly mistakes made along the way.
Parts!
Wood:
1/2":
3x - 2x4' finished plywood
1x - 2x2' finished plywood
1":
2x - 1x2'
1x - 1x4'
20x - 6x30"
10x - 8x8"
2x - 4x24"
2x - 4x48"
1/2":
3x - 4x24"
4x - 3x24"
4x - 3x48"
1/4":
1x - 3x24"
2x - 1x24"
2x - 1x48"
Note: These lengths do not take into account the thickness of the pieces they're being layered onto, so don't cut until you're at the step that uses the pieces.
Trim:
(width/thickness depends on what you choose; the rope trim used on this was approx. 3/8x1/2")
1x - 50"
2x - 26"
Other stuff:
Lots of sandpaper
1 quart of paint
Small amount of accent color paint
Applique
Wood glue
3/4" nails
1/2":
3x - 2x4' finished plywood
1x - 2x2' finished plywood
1":
2x - 1x2'
1x - 1x4'
20x - 6x30"
10x - 8x8"
2x - 4x24"
2x - 4x48"
1/2":
3x - 4x24"
4x - 3x24"
4x - 3x48"
1/4":
1x - 3x24"
2x - 1x24"
2x - 1x48"
Note: These lengths do not take into account the thickness of the pieces they're being layered onto, so don't cut until you're at the step that uses the pieces.
Trim:
(width/thickness depends on what you choose; the rope trim used on this was approx. 3/8x1/2")
1x - 50"
2x - 26"
Other stuff:
Lots of sandpaper
1 quart of paint
Small amount of accent color paint
Applique
Wood glue
3/4" nails
Base and Upper Box, Part 1
The upper box parts designated "top [piece]"; base pieces designated "base [piece]"
- Cut the 2x4' plywood pieces to 23x47"
- Cut the 1x4' piece to 12x47"
- Cut the 1x2 pieces to 12x23", less the thickness of the 12x47" piece (mine was a hair over 3/4" thick, so my sides were 12x22 1/4")
- Glue and clamp the top front and sides to a plywood piece, so the front/sides sit on the top
- Finish-sand the insides of the top box (this is a huge pain if you wait until the end)
- When that dries, glue and clamp a second plywood piece to form the bottom of the box
- Cut the 1x4x48" pieces to 47" long
- Cut the 1x4x24" pieces to 23", less the thickness of the 1x4x47" pieces, long
- Glue and clamp the base front/back/sides to the 3rd plywood piece to form the platform
- When dry, sand all joins smooth
Base and Upper Box, Part 2
- Cut the 1/2x3x48" pieces to 47 1/2" long
- Cut the 1/2x3/x24" pieces to 23 1/2", less the thickness of the 47 1/2" pieces, long
- Glue and clamp 2 of each to the top of each side of the base
- Glue and clamp 2 of the side pieces, and 1 of the front/back pieces, each to the top and bottom of the top sides and front
- Once dry, sand all joins flush
- Cut the 1/4x1x24" pieces to 24" less the thickness of the 1/4x1x48" pieces
- Glue and clamp the 2 side and 2 front/back pieces to the top of the top box front, back and sides; it should be layered onto the 1/2" pieces from steps 1-5
- Once dry, sand all joins flush
- Finish sand all surfaces
Columns
- Glue and clamp the 1x6x30" pieces into right-angle pairs
- When dry, glue and clamp 2 right-angle pieces to form a column; make sure to overlap properly so the columns are square
- Sand the side joins flush
- Make sure that both ends of your columns sit level and all are the same height
- Glue and clamp a 1x8x8" piece to the top and bottom of each column; do 1 side at a time, making sure to center the column on the base
- Again check that your columns sit level on both sides
- Finish sand all surfaces
Notes Holder Thingy
- Cut 2 1/2x4x24" to 18" long
- Cut an angle into the resulting pieces, so the front is 2" wide, ascending to 4", 2" in from the edge
- Glue and clamp these pieces to the remaining 1/2x4x24" piece
- Cut a 2x24" piece off the 2x2' plywood
- Cut the remainder of the 2x2' plywood so it is 18" wide
(The cuts from steps 4 & 5 need to be angled so the pieces will join flush when attached to the frame) - Glue and clamp the 2x24" piece to the flat part of the frame
- Glue and clamp the 18x24" piece to the angle part of the frame
- Cut the angle plywood so the front edge is a flush 180 degrees with the front edges of the frame
- Cut the 1/4x3x24" piece to 2 1/2" wide
- Glue and clamp the 1/4x2 1/2x24" piece to the front of the frame
- If your angle cutting is a precise as mine was, you'll need to fill some gaps with wood filler
- Finish sand all surfaces
Test Fit/Final Surface Prep
Put it all together, without gluing, to make sure everything looks right. Fill any gaps/dings, etc. Give everything a final high-grit sand.
Final Assembly
- Glue and clamp the columns to the base, 3 on 1 side, 2 on the other; they should be about 1" back from the base edge; make sure to wipe off any glue that squeezes out, as sanding those joins is nearly impossible without causing some damage
- Glue and clamp the top box to the base; make sure it's centered before clamping--this is the point of no return; again, wipe off any glue squeeze out
- Glue and clamp (well, sit something heavy enough to be surrogate clamp) the note holder to the top; make sure it's centered front-to-back and side-to-side; mind the glue
Paint
- Prime the whole thing
- Paint the whole thing; lightly sand with high-grit paper between coats
- Also paint the trim and applique separately; for this, it was antique gold paint, which was selectively sanded back, and in other places added to, to create a distressed metal kind of look
Attach Accents
- Attach, using nails, a long piece of trim to the top of the front of the top box; leave about an inch of overhang on each side
- Attach a piece of trim to each side
- Use a dremel or hacksaw to cut the front piece flush with the sides
- Similarly, cut the side pieces at an angle so as to blend into the corner curve at the back
- Sand the join into a smooth curve on the corners
- Touch up the paint to recover the sanded bits, and cover the nail heads
- Center the applique and attach to the front face of the top box, then touch up the paint