Step 8Seventh step. Finishing,
1. Sand everything!!! Twice!!. Remove all sharp edges and tool marks you don't want. I left some "witness" marks on mine to show off but a smooth case looks nice.
2. Varnish your wood surround. This is going to be a hard working piece that is going to be in your grubby hands a lot so apply a good wood varnish or polyurethane. 3 coats is the minimum here. Sand between each coat people will be looking at this a lot and you don't want to be shamed by a poor finish job.
3. While the surround is drying it is time to start on the cover. This is where spray glue comes in.
3a. Lay out your fabric or leather and place each one of the board on the surface leaving .25 of an inch on either side of the spine for spacing. Mark the layout and placement of the boards and cut off the excess fabric giving your self a .5" seam allowance.
3b. Coat the covers on one side with a good amount of spray glue and set in place. Adjust as needed before pressing down firmly. If you make a mistake pull it up quickly. Add more glue before reapplying. Take your time with this. You don't have anything else to do the varnish is drying.
3c. Now if you have put a logo on the cover now is the time to rub it in with the cap from a ball point pen or your finger nail. Be careful and make sure not to rip the fabric. A little water or rubbing alcohol in a spray bottle will help with this process.
3d. Rolling the edges is the trickiest part of this process. The corners always give me trouble.. So I start from the middle and work my way out the corners. I use spring clamps and take my time stretching each piece slightly one inch at a time. You can trim the edges after the glue is dry to keep things neat and tidy.
4 The inside panels. I make up some inside panels out of card stock and fabric the same way the book's covers however I am using thiner stock and thiner fabric because this is for trim and it will not take as much ware.. These panels you will want to keep about 1/16th smaller on the top and 1 side (keep the side towards the spine full length). Spray glue the card stock, and place them on the fabric. Then cut them out, spray the back and wrap over the edges. One more hit of spray glue and stick them in place.
5 If you are lucky and your surround is dry you can mount it into your cover. I use double sided carpet tape for this incase I wanted to change or modify things later. (Don't use the foam backed double sided tape because it adds thickness and it might show).
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