Augusta Museum Display Case
Spring & Summer 2011

 

          Representatives of the Augusta Museum decided there was a need for a case to display contributed World War II, U. S. military uniforms.

        The Heritage Adventurers Chapter of the Questers at Heritage of Hawk Ridge in Lake Saint Louis agreed to sponsor the construction of the display case. The HHR Questers commissioned the Heritage of Hawk Ridge Woodworking Club to design and fabricate the display case.

        The project began in early 2011 with the woodworking design team meeting with representatives of the Augusta Museum. The design evolved around the uniform display needs and the contributed arched glass for the doors. Following approval of the preliminary plans by the Museum Administrative Body, the HHR Woodworking Club members finalized the design and built the display cabinet during the summer of 2011. The display cabinet was delivered to the Augusta Museum on September 7, 2011.

        The two arched glass panels were donated by Paul Kemner and all the solid cherry wood was donated by Archie Spencer, both of Augusta. The remaining wood, glass, hardware and supplies were donated by the Questers of Heritage of Hawk Ridge. The HHR Woodworking Club gladly gave over 400 man-hours to design, fabricate and finish the cabinet.

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Starting the project

       
 

Barry (at left), along with his wife,
Mary Ann (not shown), then Questers
Chapter President,
who helped
initiate the project, Les, engineer / designer,
and Paul (right), Museum Administrative
Body member, who contributed
the glass for the doors.

 

Archie suggests the the solid cherry wood from his
storage area for the team to use on the project
.

 
         
 

Archie prepares to haul the wood he was donating.

 

Glass and cherry hardwood, ready to haul
to our Lake St Louis shops to become the
Museum's display case.

 

 
     
 
 
This front and side view provides the key dimensions 
and construction details of the display case.
 
  Cutting the one-piece cove molding on the table saw
was a new woodworking process for the team so it
was a learning experience. This plan shows
the essential design details of the upper cove
molding along with other trim and support features.
 
    The display case was sized based on the uniforms
and mannequins to be displayed. We generally
concluded in the initial visit that there was adequate
clearance through the doors and to turn the case
inside the Museum. However as the moving date
approached and the true size of the case evolved,
we began to have second thoughts. The plan at left
is the approximate path through the front door,
turning the case inside the inner hall and through
the final door. It was an extremely tight fit,
both in depth, width and length.

The two panels above are representative samples
from the set of Les's plans from which the case was
constructed.
 
         
 

Cherry hardwood is sorted, numbered, stacked
and becoming acclimated in Barry's shop.

 

Bob and Galen fine tune thicknesses on the planer

 
 
 

One of several planning sessions (Barry is the photographer).
It should be noted that the arched door glass is beveled
and we copied the style of an arched door frame to create
two cherry arched doors.
We also purchased a rectangular glass and made a fixed center frame.

Although there are no pictures of the construction of the doors due to oversight,
the doors and center frame were built in Barry's shop, right before he left town.
Near the end of May, the project was moved to Larry's shop.

     
  Les & Larry install the case back.  

The case is finally uprighted and squared on 5/31/11.

 
     
 

Galen, Mike, Les, Larry and Bill have the
basic box together.
This is when the comments began...
"That thing is huge. How are you going to get it
out of this basement?"
The 9 foot ceiling was important to this project!

 

The bottom scroll work and drawer runners are added.
The design for the scroll was suggested by and
enlarged  from an existing cabinet at the Museum.

 
     
 

The doors frames are positioned and checked
to enable the creation of the upper cross
member (shown at right).

 

Les works on upper cross member with arches.

 
 

The case is assembled prior to door installation.
The pieces clamped above the drawers are there to
support the doors for alignment purposes.

 

Glue up of drawer fronts to maintain grain match.

 
         
 

The drawer bottoms are added and then
the assembly is glued together.

 

To create these 1/4" box joints, it required 28 passes
through the saw to make each of the 4 corners
of the 3 drawers. (That's 336 cuts.)

 
         

The cove molding plan and first cut on the table saw.

Cutting the cove molding.

         
 

Cutting the 45 edges of cove.

 

After the final cuts on the table saw,
but prior to the convex surface that will be formed
with passes on a router and (much) sanding.

 
         
         
 

Larry, Les, Galen & Bob had fun working
on the project (and were happy to have
the cove cutting done).

 
 

The cove is installed -
Bob & Ron start on drawer fronts.

 
         
  A good look at the cove corner - always a challenge. 

The doors and center window in place.
It took 5 guys to get the job done.

 
 
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Finally, the case is ready for stain and finish!
 
         
 

Bob, Larry & Les staining & finishing completed.

The drawer fronts are finished.  
         
 

The last step in the shop, the lighting is added.

Wrapped & ready for transport.

 
 
         
 

New Melle Firemen start the move.

 

The case more than fills the door
as it is moved out.

 
 
         
 

Moving the case from the shop to
the trailer was a big job.

 

The cove molding was a bit too wide for the trailer
side frame, so the case
was moved forward to rest on
the front trailer frame. (Careful turning the corners!)
.

 
         
 

Heading out from Hawk Ridge.

 
 

The case arrives safely in Augusta.

 
 
         
 

Thanks to Mike, Dave & Scott,
the three fireman who provided the transport.

 

Squeezing through the Museum doors. We had
about 1" in height to clear the cove through the door
and about 2" in length inside the hallway and door.

 
         
 

Les installs the magnetic catches.

 
 

Note the similarities between the
antique and the new case (at right).

 
 
         
 

The antique case (at left) and the new display case.

 

Bob, Larry & Les, the three finishers,
who completed and installed the case.

 
 
         
  The 5 woodworkers who did the final installation at the Museum.    The location was changed to provide better viewing.   
 
The woodworkers and the Questers who went to the Museum
for the final installation.
         
         
The following 14 woodworkers spent over 400 hours in 47 work sessions.
Individual's time spent ranged from 2 hours to over 150, and all volunteered
time was appreciated.

Barry Bingham
Galen Bird (who prepared the stands for the mannequins)
Bill Copenhaver
Ron Erhle
Bob Hamilton
Orv Hollrah
Sam Huston
Larian Johnson
Bob Koenig
Bob Lamb
Larry Marten
Mike Shatzman
Les Waganer (who prepared the plans)
Perry Wood

P.S. Upon a request from Museum representatives
for additional lighting in the case,
Barry, Les and Larian agreed to install two larger LED's.
That project was done April 10, 2012. (Pictures below)

   
Preparing for the work  Newly lit displays 
   
   
Note the new plaque on the case, explaining the HHR involvement.