I told you guys, this wasn’t a weekend project. After finishing the first side of the case, I turned my attention to the small doors, because the oil based stain takes forever to dry and I didn’t want to flip the case over while that side was still wet.
Basically it’s the same process- seal the carved areas, do the mosaic, and stain. One of the doors had another additional problem. The carved circles were too deep. This meant I had to fill them in a bit with some lightweight spackle and sand the result to it created a flat base to which I could apply the tile. I also used some stainable wood fill in order to fix some minor problems with the doors.
So let’s review (we’ll be doing this a lot- there’s another 4 sections to go…) how this goes:
Here’s one of the original doors, before I did anything to it.
I then put a thin coat of shellac on the MDF to stabilize it, and then began to add mosaic tile. This has to be done in stages or you keep pushing tiles around on the wet glue. It’s time consuming, and requires patience.
I did the same thing with the other door. This door however, has a layer of spackle on top of the MDF since the chiseled portion was too deep (this happened more and more as my chisels became more dull.)
I then taped off the mosaic work in preparation for grouting. I mixed all the grout colors by hand and applied them as described previously.
That being accomplished, I turned my attention to the stain. It required multiple coats for each color. This was taken after the purple stain had been completed. (It needed two coats.) Once dry, I put a thin coat of shellac on both the purple circles and the mosaic work in order to protect it from any black stain that might get on it accidentally.
I then sanded off all the extra stain that fell outside the perimeters of the circle, and taped off all the areas I’d worked with previously.
I then started working on the black stain, which took multiple coats, with a shellac resist coat between each one in order to layer the rag effect (If you don’t apply the resist coat, the stain will just dissolve when you add another coat- the pattern you’ve applied will disintegrate.)
So one coat, leads to two…
Then I did the touchups.
Next up is side two of the case.