hello!
I'm building a hifi tube amplifier into a carved tiki head. I start with a log that's roughly 12" wide and 14-20" tall, carve a tiki face into it, then bandsaw the log in half, hollow out the insides to hold all the electronics, and bolt the two pieces back together using machine screws and threaded inserts arranged up the sides.
My problem is that the two sides of the log warp away from each other and my screws no longer line up to the inserts, so the pieces don't fit cleanly back together. Plus, I have unsightly gaps between the pieces. I could use some help and addressing this issue as I don't have a ton of woodworking experience.
--> Waiting several years for the logs to dry is sadly not an option <--
And even if it were, there would surely still be minimal warping of the two pieces that would misalign my screws + inserts.
The amp must be able to come apart for maintenance, but maintenance does not need to be performed often.
What solutions are there for reassembling logs that have been ripped this way? I don't see a ton of examples out there which leads me to believe this is a pervasive problem. One option I've considered is to bolt one side of the pieces together and have all of the warping expressed on the opposite side. The overall damage is worse but I could conceivably cover over the gap with a sliding plate. This option doesn't allow for both sides to be supported during transport, but then these items aren't meant to be moved very often.
Would sealing the wood stop warping? I haven't tried this, but again, even minimal warping would thwart my strategy of machine screws + inserts.
Another option is to leave the shell of the log intact and hollow out the interior from the two ends. This poses some challenges with the wiring but feels like the best option for presentation. I should also be able to cut out an access port in the back and use the cut-out piece as a hinged panel without any warping, correct?
pictures attached. I'm not worried about the little splits/checks in the log, just the large gap that opens between the front and back halves. The second picture is a top view; the small holes are for ventilation, the larger hole is in the center of the pith in a vain attempt to slow the movement.
any other suggestions welcome! thank you!
earl1.jpgearl2.jpgearl3.jpg