Constructing
the Shell
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The shell of the dollhouse is constructed from seven
ply marine grade plywood - an extremely stable wood under changing
temperature and humidity conditions. Since I had neither the skills nor the equipment to build the shell, it was contracted out to a pair of wooden boat builders at a cost of $7,000. The complete dollhouse is much too large to pass through a door frame, therefore we needed to construct it three sections; the base, the first floor and the second floor, so that it can be disassembled for moving. The Base The base measures 43" by 55" and is reinforced with 1" by 4" oak sides and bracing under the platform to maintain rigidity and to keep it from warping. The base also contains the foundation which is made from 1" by 3" birch strips. In each corner of the foundation is a 3" by 3" block with a 1" diameter hole to receive a 1" diameter round peg mounted under the base of the first floor. This allows proper positioning of the first floor on the foundation. The First Floor The first floor base measures 40" by 40". Slots 3/8" wide and 1/8' deep are routed in the floor and in the interior and exterior walls to properly position the walls. The walls were then glued into place using West System Epoxy. In places where the routing overruns the walls, the space is filled in with West System Epoxy and sanded to a flat surface. Underneath the first floor are mounted 1" diameter pegs to fit into the holes on the base. In addition, the outer walls overhang the foundation by approximately 1". The Second Floor The second floor also measures 40" by 40". Again, slots are routed into the base and walls to position both the interior and exterior walls which are glued with West System Epoxy. In addition, the outer walls extend beyond the base of the second floor by about 1/4" and has a lip routed into the wall. This lip fits into an opposite directed lip routed into the top of the exterior walls of the first floor so that the second floor can be properly positioned. The second floor also contains the ceiling of the second floor which also serves as the floor of a small attic. All of the electrical wiring leads to this attic where the switches are mounted. |