I recently made a small wooden mirror from a piece of walnut with some awesome figure. I already had the mirror, so I reused it. Read more to see the steps I took to make it...
First, let me share with you the tools I used in this project.
Pre-cut craft mirror (oval shaped) - http://amzn.to/2lYxMJd
Spray adhesive - http://amzn.to/2levime
Bandsaw - http://amzn.to/2lez3YX or http://amzn.to/2leku7M
Router - http://amzn.to/2mcO0yV
Disc sander (different version) - http://amzn.to/2lALfnP
Files - http://amzn.to/2lev7aE
Dremel - http://amzn.to/2mcNQHJ
Sanding sponge - http://amzn.to/2lKOP0M
Epoxy - http://amzn.to/2lAOiMJ
Foam brushes - http://amzn.to/2kRKzxi
Polyurethane - http://amzn.to/2mcORj3
See our other tools here.
I started by making a template of the mirror out of paper so I wouldn't have to carry the mirror around in the shop. Next, on another piece of paper I drew what I wanted the mirror to look like creating a template and used spray adhesive to glue that to the piece of walnut. Once the template was glued in place I took it to the bandsaw and cut out the shape. Below are some images from the first few steps in the project...
After I get the shape cut out, I can start working on the handle's shape. I do this a few different ways. The first is by tilting the bandsaw table to knock the edges off by running the mirror handle backwards against the blade. Then, I use the disc sander to round over the end of the handle. The last thing I do to help shape the handle is use a round file to work out the saw marks. I also used the router to put a small round over on the remaining edges of the upper part of the mirror. Take a look at the images below for a visual of what I did...
On to the mirror itself. First, I sanded away all the paper that I previously glued on then I took the template I made for the mirror and traced it out on the piece I just finished shaping and began hogging away the waste to create a recess for the mirror to sit down into. I first tried carving chisels to get rid of the waste, but I quickly realized that was going to take a while, so I switched to the Dremel. This made quick work of sanding away the area needed for the mirror. I used the Dremel to get as close as I could to the line then finished sanding with a sanding pad. This allowed me to sand right up next to the line and also smooth out the bottom of the recess so the mirror would sit flat.
The last few steps in the project were to use epoxy to hold the mirror in place. The epoxy I used comes in a two part container and dispenses both parts at the same time, so all you have to do is mix it up and apply it to the area where the mirror will sit. Let that dry for a good thirty minutes. After the epoxy has cured, the finish can be applied to the entire mirror for a nice look. Once the finish dries your mirror is complete.
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