Building the Black Gate
Part one: The Gateway
© Lotrscenerybuilder 2008
We continue our work with the panelling of the door frame. Copy the Sam A element onto a sheet of 1mm cardboard (This is going to be a very precise job!).
After drawing a rectangle of 9.4cm x 17.0cm, draw a strip (0,8cm in width) at each of the sides. In between, draw these strips of 0.55cm by using alternately a red and a black pencil. We're going to make incisions on the red lines - but not yet.
At a height of 5.8cm, draw a horizontal line (it's the dotted line on the template; it's not in the picture above). This line is going to be a guideline for some decorations later on.
Use a metal ruler to guide your hobby-knife while separating the Sam A-element from the cardboard sheet.
Copy the Sam B design on the backside of the rectangle. Study the template carefully. Again, draw both lateral 0.8cm strips first. Next, draw two strips of 0.55cm before filling in the other thirteen strips of 1.1cm. Use a red pencil.
If all went well, there should be red lines on the front and back in an alternating pattern. Use the ruler to make a 'halfway' incision on every red line, on both sides.
Start bending the strips back and forth: one by one, from left to right. The result should be a 'harmonica-sheet'. Take care to bend the strips completely by pressing them tightly together.
Glue the 0.8cm strip to the side of the front-frame. Make sure that 0,4cm of the cardboard coincides with the 4mm side of the front panel; that leaves another 0.4cm of the 0.8cm strip running free from the wood (if this sounds too cryptic for you: just study the next pictures & hope for the best…).
Now if you stretch the harmonica-sheet you will see that the ridges pretty much coincide with the 1.0cm lines on the MDF (probably some physical law at work here…).
Put some glue on the inside ridges of the harmonica sheet, as well as on the other 0.4cm side of the front panel. Next, stretch the harmonica-sheet and glue the lateral 0.8cm strip on its proper place.
Press the front gently against the table for a while, to force the ridges getting attached to the MDF.
We are going to mask the incisions in the cardboard by using painter's tape. Easiest way to do this is to stick a length of tape on (the cleaned! surface of) a table and draw fifteen strips of (about) 0.6cm x 8.0cm.
Next, cut out the strips and stick them onto the ridges (as you can see in the pictures we made a mistake by using only 6.0cm long strips; we had to correct this fault at a later stage…).