10-21-2013, 05:48 PM
The main problem I faced was that the scrollwork bowed outward about 1/4". It would really be noticeable with grill cloth behind it. It needs to be as flat as possible. I tried pressing it down and gluing it, but that wasn't going to work. It kept popping back up. I decided to, very gently, re-break all the pieces. I then removed a sliver from each piece by lightly running it across 220 sandpaper . I couldn't photograph while doing this. The idea was to just remove the tiniest bit of wood. Too much removed, and the grill would not fit back together. It involved, sanding, test fitting, sanding, and fitting some more.
Once happy with the fit, I used wood glue and bent bobby pins to clamp it all together. Sometimes you gotta get creative, the entire thing is like a house of cards.. and a regular clamp won't work.
The artist formerly known as Puhpow! 8)
