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Picture of Black Walnut Slipcase for a Prized Book
I bought a new Greek New Testament that is the same size as a dictionary I already had.  I want to be able to carry both in a canvas bag, but without something prying its way between the pages and crumpling them.  I decided on a wooden slipcase from black walnut.  This is it all finished.
 
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Step 1: Material

Picture of Material

This is the piece of black walnut I used.  Someone was discarding it.  It is 9/16 inch thick, about 6 inches wide, and about 18 inches long, more or less.  It has some nice grain figuring in it, but there is also a knot in that part of the board near the far end.  The part directly around the knot is not useful.

Step 2: Exploded diagram

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This is an exploded drawing of all of the parts as they fit together in relation to one another.  They will be glued together without any nails.

Step 3: Begin cutting

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The first step was to take physical dimensions of the two books I want to keep in this slipcase.  I do not want the books to fit either too loosely, nor too tightly in the slipcase.  I held them together and lightly very squeezed them while I measured their thickness.

I figured I would use 1/4 inch rabbets on the top, bottom, and back.  That meant allowing 1/2 inch extra in the length of the side pieces.  Allow a little more extra just to avoid getting yourself into a corner.  You can always cut off a little excess, but it is almost impossible to add something back if you cut too much away.

I wanted the side pieces to be about 1/4 inch thick.  I also wanted to glue the sides up from several pieces so I could alternate the circular pattern of the tree rings up and down to reduce the effect of any cupping.  Wood will always move with changes in humidity. 

I cut pieces from my board about 1 1/2 inches wide.  Then I re-sawed those pieces on my bandsaw.  I first tried clamping a guide fence to the bandsaw table, but the blade wandered and I wasted a piece of wood.  I got much better results by drawing a line and following it. 

Step 4: Smoothing

Picture of Smoothing
A bandsaw blade leaves quite a rough cut.  I needed to true and smooth the edges and the surfaces of the strips for the sides of the slipcase.

The sanding drum is on my radial arm saw.  I feed the wood into the rotation of the sanding drum.  I take very light cuts and keep the wood moving to avoid any burning.  If you look closely you can see blade marks from the bandsaw on the piece in the foreground.

Some blade marks were deeper than I expected.  I did not want to make all of the pieces so thin as would have been necessary to eliminate all blade marks.  I decided to make one side good on those pieces and let the side with the blade marks be inside the slipcase where no one will see them. 

I am using a small raised table to bring the work up to the sanding drum.

Step 5: Truing the edges

Picture of Truing the edges

I also needed to true the edges as if run through a planer, but I do not have a planer.  I used this setup with my sanding drum.  Again, feed the work into the rotation of the sanding drum.  I used a framing square for a fence.  After a piece has been sanded this way, loosen the clamps on the framing square just a little.  Move one end only a few thousandths of an inch closer to the sanding drum and tighten the clamps.  Pass the wood between the sanding drum and the fence again, turning the wood over to sand both edges.  When prepared this way, the glue joint fits very tightly and is difficult to see.  (The piece shown here actually became the top and bottom of the slipcase.)

Step 6: Strips ready for gluing

Picture of Strips ready for gluing
Here are the strips surfaced and with straight edges added. 

Step 7: Glued

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Here the strips have been glued and clamped to make one larger piece from which the two sides will be cut.  Clamp well until the glue is dry.

Step 8: Smoothing the glued up assembly

Picture of Smoothing the glued up assembly

I used a sharp chisel as a scraper to remove excess glue and to smooth any edges that were high. 

Step 9: Some sanding

Picture of Some sanding

More sanding will be needed later, but I used a belt sander to remove any hills and valleys in the surface of the side pieces.  Use a fairly light grit sandpaper and keep the sander moving so it does not cut too much in any one area.

Step 10: Cut the sides to width

Picture of Cut the sides to width

Look carefully at the grain figure and choose where you will cut to make two sides.  I did some planning when I was laying up the strips for gluing and decided to cut from each end of the larger piece. 

Step 11: Square the side pieces for length

Picture of Square the side pieces for length

I cut both side pieces for square and to length at the same time.  One is on top of the other in the exact orientation planned for their use in the slipcase.  Even if something is not quite right, the pieces will be identical and will fit.

Step 12: The top, bottom, and back

Picture of The top, bottom, and back
I cut one piece similar to this one for the back, although it was only as long as the sides are high.  (See the parts diagram in step 2.)  I also cut this longer piece to use for the top and bottom, but I planned to do something different than what might be expected. 

The grain on the sides is vertical.  That means most of the shrinkage or expansion with changes in humidity will be side to side.  I decided I wanted the grain in the top and bottom to match the sides in its direction.  If you have ever seen a crack in a tabletop, etc.; the pieces were assembled so they could not move without grain running in another direction opposing that movement, and the wood eventually split.  This is a small project and there might not be much movement, especially in black walnut.

The piece you see was cut into short pieces equal in length to the width of the top and bottom.  Again, leave a little extra to cover any mistakes, etc. later.  See the next step for a photo.

Step 13: Gluing up the top and bottom pieces

Picture of Gluing up the top and bottom pieces
Here I have glued up the shorter pieces so the grain can run in the same direction as that on the side pieces.  A top and a bottom will be cut from this assembly.  The edges will need to be trued first as in step 12.

Step 14: Check the fit

Picture of Check the fit
Lay up the pieces you have so far.  Measure for closer fitting and cutting.  The top and bottom can be trimmed to length.  Then some rabbets will be made on a router table.

Step 15: Check settings with a scrap of wood

Picture of Check settings with a scrap of wood
It is easy to become confused when setting up rabbets with a router table and set the height as if it were the width, etc.  Use a piece of scrap wood to make cuts that prove your settings are correct before cutting on your good pieces.

Step 16: When finished routing rabbets

Picture of When finished routing rabbets
When finished routing rabbets, you will have three pieces that look like this.  Be careful when routing.  Part of a finished edge can chip away very easily as the bit exits the wood.  You might slowly back the back end of the wood into the router bit to remove the last part of the cut first and eliminate the possibility of marring the finished surface with a missing chip.

Step 17: Check fit before gluing

Picture of Check fit before gluing

Do a dry fit to make sure everything will work when glued.

Step 18: Final assembly with glue and clamps

Picture of Final assembly with glue and clamps

Here you see the slipcase glued and clamped.  Do what you can to check that the assembly is square.  Scrape off excess glue as soon as is practical. 

When dry enough, remove the clamps and sand with successive grades of sandpaper for a really nice finish.  I used Danish oil for my finish. 

Step 19: Done

Picture of Done
Here are my two books in my new slipcase of black walnut.  The books are protected and the slipcase should last for many years, even carrying it with me.
80$man3 years ago
Very good ibble Phil! This would be great for a gift, it is more personal that just giving a book and one could inscribe the slipcase!
Like your choice 'valued' books, I will make my dad a slipcase for his "hebrew and English lexicon of the old testament". Many thanks!
Phil B (author)  80$man3 years ago
Thank you. I have been carrying that slipcase daily in my canvass bag. The slipcase has held up well with very few wear marks. It also keeps my prized Greek/German New Testament like new. It sounds like the Hebrew - English lexicon could be Brown - Driver - Briggs. I think I wish my Hebrew were as good as your father's, but I will work on that.
IzNoGuD4 years ago
Das neue Testament?

Ich darf Ihnen gratulieren, ich genieße Ihre Anleitungen sehr.
Sehr viele nützliche Ideen, Danke Sehr.
Phil B (author)  IzNoGuD4 years ago
Recht herzlichen Dank für Ihre Bemerkungen. Ich bedanke mich bei Ihnen, dass Sie meine Anweisung probiert haben. Ja, ich bin ein lutherischer Pfarrer in den Vereinigten Staaten, und fast täglich benutze ich mein Deutsch. Die deutschen Theologen geben vielen guten und hilfreichen Bescheid. So habe ich einige Studienbibeln, usw. aus der Deutschen Bibelgesellschaft: Stuttgart.

Stammen Sie aus Deutschland, oder?
IzNoGuD Phil B4 years ago
Nein, ich bin aus dem Osten in Österreich aus einer 50:50 Gemeinde (evang. AB / röm kath.).

Also sind Werkstücke aus Ihre Anleitungen nochmals 500km weiter östlich zu finden ;).

Ich bin wirklich begeistert über Ihre handwerklichen Fähigkeiten und Ihr einwandfreies Deutsch.

Liebe Grüße aus Österreich.und weiterhin gute Gesundheit und viel Erfolg
Phil B (author)  IzNoGuD4 years ago
Noch einmal, recht herzlichen Dank. Ich bin dem Herrn Gott dankbar, dass ich einige Fähigkeiten habe. Auch habe ich während der vielen Jahren viele, viele Übung. Noch mache ich viele Fehler. Das wichtigste ist üben, üben, üben.

Auch bin ich Ihnen dankbar, dass Sie mir und meiner Projekte jetzt folgen.

Vor einigen Jahren hörte ich oftmals Radio bei der Kurzewelle an, und oftmals hörte ich Radio Österreich gern an.

Alles Gute!
cbm1044 years ago
Functional and beautiful, very nice!
Phil B (author)  cbm1044 years ago
Thank you. I use it everyday. So far it has not picked up more than a couple of very small dings.

One thing I wanted to do in this Instructable is explain some basic aspects of woodworking that could be applied to many other projects, like gluing up a table top from cabinet grade hardwoods.
rimar20004 years ago
VOTED!
Phil B (author)  rimar20004 years ago
Thank you, Osvaldo.
You're a genius! I had been working on how to protect a concordance, commentary, dictionary, and others that I frequntly transport. I had been thinking of making a rolling bookshelf (like a small travel cart), but it would be a bit heavy. I'll be making one of these! I may make my first instructable to show how to make reading/studying multiple books easier. Excellent job!
Phil B (author)  OnlyUsernameAvailable4 years ago
Thank you for your comment.

If you have access to some veneer plywood, you can use that for the side pieces rather than re-sawing, fitting, and gluing up the side pieces. I made one of these years ago for a Bible with soft covers and used 1/4 inch walnut veneer plywood on the side pieces. I glued a strip of solid walnut over the exposed edge. The only disadvantage is that the veneer is very thin and any scratch could go down to the plywood substrate.

A slipcase like this works well for multiple books if they are very close to the same size (except perhaps for thickness). I wish you well with your project. Please show us photos when you are finished, or a complete Instructable.
Is there anything you do use your Arm Saw for??? Just another face palm moment, why didn't I think of that. Love this!
Phil B (author)  RedneckEngineer4 years ago
Did you mean, "Is there anything I do not use my radial arm saw for?" I can now afford more tools than I ever thought possible, but bought it because of the many operations possible with a radial arm saw together with a few jigs and accessories. Thank you for looking at this.
Looks like my fingers don't always follow what I think, at least you knew what I meant.
Phil B (author)  RedneckEngineer4 years ago
Thanks. I am not sure my response made as much sense as I intended. I bought the radial arm saw with the intention of getting as much as possible out of it because I never expected to have enough money to buy various individual tools. I also got a 30 per cent discount back in 1972 because they were introducing a new model and needed to move these out. It has worked out well for me, although sometimes I have had to take down a setup to do another operation and then had to duplicate the previous setup.
rimar20004 years ago
Good work phil, and what a beautiful wood!
Phil B (author)  rimar20004 years ago
Thank you, Osvaldo. I see Argentina has its own type of walnut with even more figure and darker than our North American black walnut. You must have some beautiful furniture available in Argentina made from it.
Probably so, but I have understood that it is a very expensive wood. I searched for "nogal" (walnut) on Mercado Libre (argie eBay) and only found used furniture, most veneers. It is known that antiques do not have a standard price, each worth according to the circumstances surrounding it (and what the buyer is willing to pay). Maybe if you come to Argentina and see the price of antique furniture you salivating, but they are very expensive for us.
seolfor4 years ago
Very nice. I like that you used someone's "trash" wood for this project. It looks very good. Thank you for sharing.
Phil B (author)  seolfor4 years ago
Thank you for your interest and your comment.
mikeasaurus4 years ago
"step 1: ..Someone was discarding it.."
disgraceful!

Great job on the reuse, the slipcase looks great with the Danish oil. Love the texture
Phil B (author)  mikeasaurus4 years ago
Thank you. There was a small cabinet shop across the street from us. It had been closed after the death of the owner. His sons opened it again for a few months and then decided to convert it to a house and sell it. About the time of the final closure they set out quite a few wood scraps. Most of it was kindling, but I was watchful and got a few pieces of cabinet grade hardwood. But, I felt really sick one day when a tree west of our small town was cut and sectioned like firewood. From my bicycle I could smell the distinctive odor of black walnut.
Sabata Phil B4 years ago
The slipcase is beautiful, Phil!

I feel your pain re: the black walnut tree turned into firewood. A neighboring church once did the same thing to a black walnut tree during an expansion project. I wanted to cry.
Phil B (author)  Sabata4 years ago
Thank you. Seeing a walnut tree destroyed needlessly reminds me of a story from a friend. Someone he knew had kept a box of baseball cards from when he was a boy. Included in it were some very rare cards. His wife wanted an addition to the house, but they could not afford it. One day she went on a cleaning rampage and tossed his box of baseball cards. He told her, "You know those cards you threw out, well, some of them would have paid for an addition to the house." I do not know what was said after that.
omnibot4 years ago
Nice job and good idea for keeping books safe.
Phil B (author)  omnibot4 years ago
Thank you. A black walnut slipcase would be overkill for anything but a very special book. A simpler slipcase of cardboard would be good for a more ordinary book.