One sheet MDF wainscoting Project

[myxpykalix]

One sheet MDF wainscoting Project. I finally got it cut and finished (almost). All this was cut out of a single sheet of mdf. The design is a hodge podge of a bit here, bit there combined. It has a 3" shoe molding at bottom with 4" rosettes with a 4" wide fluted rounded pilaster. Along the top is dentil molding which will be capped off by a chair rail. It stands 34" tall by 8' long. the raised panel is 24"x24". This is the most ambitious project i've done so far and the most time consuming. I could have done this in half the time by doing it the rail and stile method, but then why did i spend 15K on a shopbot?
Here is a link to more pics as i can't post the quality of pic here due to size limitations:
http://i126.photobucket.com/albums/p...inscoting1.jpg
There a 4 pics there just substitute the 1 for 2, 3, 4 not sure if they will all come up otherwise, first time i posted there.
I couldn't have done all this without some GREAT help from some GREAT guys. Bill L, Gerald W, Ed L, Carroll, and Jimmy A(*) and all the guys who have answered all my hundreds of questions. Hope i didn't leave anyone out. Thanks

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[fleinbach]

Great job Jack!

I had planned on doing the same quiet some time but it has always been placed on the back burner. You've inspiared me to maybe get started on my own. It looks like you chose the two layered method for depth. It worked out very well.

[cbradshaw]

Great Job Jack!

I could not see the other pictures.

Carroll

[dmidkiff]

Jack,
Good job. please post pics when on wall. Bet it is awesome.

Dave

[Towersonline]

Great job Jack !! Thanks for posting the results of your efforts.

To view Jack's other images .... in your browser you will see the web address, at the end you will see the words shopbotwainscotting1.jpg just change the 1 to 2 and hit enter.

Bill Thorpe

[drodda]

Jack,

That is one of the coolest things I have seen someone make with the bot. Great Job and thanks for sharing this with us.

When do the classes start? You are going to show us how to make these panels aren't you?

-D

[myxpykalix]

I would be considered a "student teacher" having been taught by some of the "Professors" here. I had a lot of help in the design phase with the rounded fluted pilasters. I will try to put some pictures and descriptions together.

[jhicks]

Jack, am I assuming this is 1" thick MDF or trupan?
Looks great. Approximately how long was the cut file and I assume multiple bits, correct?

[myxpykalix]

If you look at the pic, you'll see that the bottom sheet has 3 designs in it and on top of it you have a 3" shoe molding that the fluted rounded pilasters sit on that the dentil molding sits between. The bottom sheet is 3/4" mdf the pilasters, dentil molding and shoe molding is also 3/4" mdf. The total thickness for both layers in 1 1/2". All parts were cut out of a single piece of mdf. The raised panel and carving in the center takes 8 toolpaths and takes about an hour to cut all of them.I inserted "accent lines" to mimick the look of joint lines to make it look like traditional rails and stiles. The rosettes/rounded fluted pilasters take about an hour each to cut the "roughing" toolpath and frankly it looks so nice that i haven't bothered to cut the finishing toolpath. The dentil molding takes about 20 min or so. Its a combination of 1/4" endmill and a "plunge button" bit to make the button holes. To join the panels together I am cutting it approximately in the center behind where the pilaster will go. That will hide the seam all the way up.

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[myxpykalix]

Wainscoting finished on one wall (except for a cap piece on the far end). Total time in machining was about 10 hours for 2 panels with the pilasters, dentil, & top rail. Probably double that in designing and toolpathing. Bob L. Helped with the rounded fluted pilasters which i think is the best part of this. I could have done flat pilasters but i think the rounded pilasters are much cooler.
I set the panel up to the wall, leveled and squared it, screwed it to the wall and then brad nailed the parts over the screws and placed the joint between panels strategically behind one of the pilasters so you see no joint. It only took about 20 minutes to screw and nail it up, that was the easy part.
The way i calculated this it all came out even except for the end by the far door. I need to make a 3" wide pilaster, the others are 4". But i'm pleased with it.

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