I picked up this sticky backed world map cork board a few years ago, but the room to tack things to it was very limited and the adhesive started to fail after moving it around a couple times. I decided to finally do something about it!
I urge you to check out the build video to see the whole thing come together. Links to all the products I used in this build can be found in the video description.
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Step 1: Wood Selection and Prep
I made this frame to fit the roll of cork I purchased which was 24" X 48". I selected a single piece of walnut and cut it down into three identical strips. I cut one of those pieces in half and taped the two short pieces together. I also taped the two long pieces back together before cutting everything down to length on the tablesaw. This ensures that the short rails and the long rails are exactly the same size.
I then used a marking gauge to lay out my cuts for a bridle joint. I mark the pieces that I'm going to cut away with a sharpie so I dont make any mistakes.
Step 2: Cutting Corners
I whipped up a simple tenoning jig which allows me to vertically support the pieces while cutting the two halfs of the joint. I line up the cuts as best I can and slowly sneak up on the cut line I marked in the previous step. I switch back over to the tablesaw sled and cut the cheeks off the short rails. I clean all the corners and edges up with a chisel or two and test fit everything before gluing and clamping the frame together.
Step 3: Finishing Touches to the Frame
Once the glue is cured, I route a groove in the back side of the frame to accept the cork assembly I build in the next step. To dress up the frame a little, I add 5/16" brass pin inlays to the corners, and 1/8" brass pin inlays to the center of the long rails.
Step 4: Pop That Cork!
The roll of cork I picked up was 24" X 48" and roughly 1/8" thick. To add some rigidity and also some depth for the push pins to go into, I used spray adhesive to attach a piece of cardboard to the cork. I used some gray and blue paint to add a hint of colour to the cork backer board so the world cutouts would pop a little. The map pieces were purchased from Luckies of London - http://amzn.to/2fiq5ex . The pieces have an adhesive backing, but since I had moved my map several times, I used spray adhesive to permanently attach them to the cork backer board.
Step 5: Almost There!
I gave the frame a coat of Danish Oil which did a great job of bringing out the beautiful grain of this wood and increased the contrast of the brass pins. Once the finish had dried, I stapled the cork assembly into the frame from the backside.
Step 6: Hang It / Fill It
This frame is hanging in my office at home and it is working perfectly so far! Lots of room to pin everything and a very classic look. I urge you to check out the build video to see the whole thing come together. Links to all the products I used in this build can be found in the video description.