The Golden Disk Of Amun Re - MAGifacturing Process
Many old-timers believe that hand carving is the only art form when sculpting but as you see there is a lot of modeling that takes place in the computer which can be added to or removed. Without the ability to "see" the David in a block of marble, I would not be able to create the art on these projects. The only people who believe that hand carving is superior to CNC are those who can not afford CNC, in my opinion.

The computer simulation, to the left is what you see on the monitor. Programing requires you to select the speed of the cutting bit, how many passes from top to bottom, the speed the machine travels, the direction or multiple directions of various cutting strategies and dozens of other peramiters which vary on different materials. This knowledge only comes when you marry your machine.

After seventy five hours of computer sculpting for the cabinet alone and machining dozens of samples, the final design was ready.

The next descriptions will illustrate the manufacturing process for this project

First the wood is anchored to the bed of the machine, the selected cutting bit is installed, the position to start cutting is established and only then does the real machining begin.

In the photo to the left the bit has already begun cutting. It takes 450 passes from one end to the other while traveling from the right side to the left. The cutting bit rises and lowers automatically to create the relief.

The entire cutting process is digitized , "CNC" stands for (Computer Numerically Controlled). It is a very bad idea to turn the machine on then leave the building. Parts occasionally come loose and create all kinds of havoc.

Each photo was captured at approximately 15 minute intervals. The total time to machine this frame is just over an hour. side panels take approximately an hour and a half. The front takes approximately the same.

Philippine mahogany is physically lighter then African Mahogany and is a top choice of fine furniture makers all over the world. I selected Philippine Mahogany because the cabinet may be picked up during the routine and a lighter wood is easier to handle using one hand.

Experience has shown that Mahogany is a very fuzzy wood regardless of the species. Why it ever caught on as "fine furniture" wood is a mystery because it requires extra attention to hand sand however the finished product is beautiful, so we've just answered our own question.

Another improvement over the original was to do away with the top of the cabinet. Allowing light to enter from above lets the audience see the effect better. By removing the top and adding a frame on the front, the performer is not subjected to bend over, showing the top of his head, while removing and replacing the disk. Something always bothered me about the three previous versions and It didn't connect until I started looking at Egyptian architecture. Older versions had a rounded panel which was akin to an arch.

It's generally agreed that Romans invented the arch yet the front panel on Reidel's (then Swogers) model were rounded. This aspect was not true to the time period so I altered the front to be more representative of the later Egyptian architecture. If you study various pictographs on the interior walls of pyramids you will notice how depiction's of structural columns were slimmer at the bottom. That design element was also incorporated on the front of the cabinet.


Making the panels thinner then the store bought wood was also important because thinner panels accentuate the carvings. You have to be careful when selecting the wood to make sure the grain is tight and straight to produce a finished product that is also straight.

As you see the cutting bit has made it's rounds and the carving is complete except for removing the central opening and cutting the panel it free from the surrounding material. There are several methods for stabilizing the wood to insure it does not come free and bounce into the cutting bit. If this were to occur (and it has) that piece is discarded.

There is a difference between naturally occurring flaws in wood and an obvious attempt to hide a mistake. Natural materials vary and that's what sets them apart from resin-cast products or something made from inexpensive materials then painted over. There are variations in all wood products but that is their nature. Each one is therefore different.

For rather selfish reasons the method for holding the panel while cutting it away from the surrounding material is not shown. No need to give away all the secrets. It's been a five year odyssey learning about working with CNC and most of what has been learned is different from table saw methods and hand-tool techniques,

As you see, the Mahogany is exhibiting it's normal tendency to be fuzzy. Sanding is up next. There are no fancy machines for this process, it takes three grades of sand paper and good old-fashioned elbow grease. The finishing procedures will also not be shown because of the years it takes to learn their secrets.

After a good twenty five minutes the fuzzy ends have been sanded. Multiply that by all the number of individual pieces and you have sanded two hours preparing the wood before assembling. More sanding will be required as the pieces are assembled. At this time different pieces are matched to each other so the panels have similar tones and grains. You'll most likely see lighter colored wood on the back panel and bottom. This on done on purpose because If the carved panels are deeper and richer, in color, they will stand out against the lighter tones. If however the side and front panels all have variations in tones then the lighter back panel is of no concern.

These two pictures shows the wings before and after sanding.

Notice the resemblance of these wings to this advertisement from Tampa LINk.
An essential part of the modus operandi is the need for an opening in the bottom. Without giving away too much. it's safe to say that one of those oblong pieces is free to move but more importantly should someone sitting in a chair be looking up under the cabinet they will see what appears to be a decorative bottom as opposed to seeing a hole. (See movie). It takes another hour to assemble the cabinet and sand the bottom flush. Unfortunately we can not discuss the methods and techniques of how this piece is finished except to say there are up to 12 coats of finish on each cabinet after the flocking has been applied, I didn't mention making the gimmicks because you'll see them when the package arrives. An interesting fact about the feet is that these were the original Chink A Chink's.
The magic wand is made from brass and the tips are Bakelite, yes Bakelite. We have a supply of Bakelite in various colors and decided this was a good a time as any to use them.
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